RFID-based real-time data acquisition system solution for garment production line
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Project Background
At present, large and medium-sized garment factories in China (with more than 1,000 sewing machines) generally adopt a non-automatic manual assembly line production method, and the production process is basically the same. The typical production process is as follows:
The cutting department picks, spreads, cuts and fills in the cut sheets according to the production plan;
After cutting, bundle the multi-layer garment pieces of the same part according to the rules of size, cloth layer, color, etc., and bind the binding slip entered and printed out according to the cut sheet to each bundle of garment pieces, and the piece of clothing is recorded on the binding slip. Attributes, such as style number, size, color, batch, cutting bed number, and process number, bundle number and number of pieces;
The sewing workshop goes to the cutting department to receive the bundled pieces, bundles the pieces of the same bundle number together according to the production process, and delivers them to the corresponding workstations by hand;
Workers at the station receive the garment pieces and perform the required procedures. After the operation is completed, they sign the job number on the stub, and cut off a piece (called a fly) on the stub to calculate the piece wages. certificate;
The tie-up worker collects the semi-finished products completed in the previous process, bundles it with other parts of the same tie number again, and manually transfers it to the next process;
Repeat steps 4 and 5 until all processes are completed, and the finished product is packaged and put into storage.
The function of the binding sheet is to indicate the attributes of the garment pieces, the batch to be cut, indicate the processing procedures that need to be performed for the garment piece and the number of products in this batch, and record the workload information of each station. After the fabric is cut, the workers rely solely on the information on the binding sheet to perform production operations to ensure that each piece of clothing is sewn from the same attributes in accordance with the planned process. At the same time, the workers who perform each process also have to settle the piece-rate wages with the reserved slips. Therefore, the tie-up is a key tool that links all production operations together.
demand analysis
The management of production through the use of tie sheets is a set of current solutions summed up by the garment industry after years of exploration. This set of solutions is simple and practical, and matches the overall informatization level of the garment industry. However, with the continuous improvement of customers’ demand for rapid response production and visual production supervision, the management method of tying orders has revealed many areas for improvement:
The monitoring of the production progress only stays on paper, and the workshop summarizes it once every day after get off work. In this way, the production management department cannot accurately grasp the production progress in real time. The result of this state is that the information of the company’s decision makers is lagging, so the production status cannot be immediately understood, and the production capacity cannot be accurately grasped, which affects the later production planning and arrangement and lacks decision support for order negotiation.
99% of the workers’ remuneration system in the garment industry is piece rate. The current wage calculation method adopted by the garment industry is to calculate the workload by counting the worker’s signature record on the stub and the worker’s cut-off slips, and then multiplying it by the unit wage to get the wages of each worker. This work requires a lot of manpower, is error-prone, and often causes disputes. In addition, since it is impossible to record the time spent by workers in each process in real time, the approval of the labor cost for each process is very subjective, and it is easy to cause disagreements. Therefore, almost every day in garment factories, workers have objections to wages.
The content of the bundle cannot be flexibly customized. Because the current binding slips are all printed on the printed binding slips, different product information can only be printed on the binding slips in the same format. Sometimes the cutting workers need to write by hand to supplement the content. The main reason for the above problems is that the paper bundles cannot meet the requirements of real-time and accurate production information collection, sorting and analysis. Manually recording the completion status of the main processes and counting the completion time of each process with a stopwatch is the only production information collection method in the garment factory at present. The tie-up is the main clue to track the production progress of each batch of products. Through this information collection method, only lagging information feedback can be obtained, and production plans and business decisions made based on this will inevitably have errors. Therefore, the real-time production information collection method is the key to improving production efficiency, optimizing management methods and obtaining decision support for garment manufacturers.
solution
Electronic binding cards using RFID technology are used instead of paper binding slips, and the processing information is recorded in them and tied to the garment pieces. The electronic tie cards are transferred to each process along with the garment pieces; RFID data collection terminals are arranged in each station, and all reading heads are connected to the main server to form a system network. When the garment pieces are transferred to the specified process for processing, the worker scans the electronic binding on the data collection terminal, and the system records the start time of the processing process. After the processing is completed, the worker presses the end button to notify the system that the process has been completed. Each employee is equipped with an RFID work card, and registers with the work card when entering a station, so that all operations performed by the station are associated with the employee’s work card, so as to realize automatic statistics of workload, automatic settlement of wages, and Trace quality responsibility.
The preliminary design of the specific application plan of the electronic tie card in each link is as follows:
1. Issuing electronic tie cards
After the cutting department cuts the fabric according to the production instructions issued by the production management department, it fills in the cutting report as usual and sends it to the workshop office. The workshop office staff uses the electronic binding creation program to enter the cut sheet information into the system. So far, the batch of products is required All the contents of the bundles used have been generated.
The cutting department called up the bundle list of the batch of products, used the electronic bundle release program to select the corresponding bundle entry for the pieces to be bundled, printed the paper label, and wrote the generated bundle information into the electronic bundle at the same time. Then tie the paper label and the electronic tie card to the garment piece. If you use a rewritable label printer, you can print visual information and write electronic label content in one step. The garment pieces that need outsourced processing (such as embroidery) are also bundled with electronic binding. The outsourced process should be regarded as a normal process and recorded in the production progress tracking system.
2. Production preparation
After the production plan is issued to the designated production team, the team leader uses the process management program to arrange the workers at each station to complete each process; in the production process, each station can only execute the specified process, otherwise the system does not support it, but the team The manager can make adjustments according to the production schedule and change the correspondence between workstations and processes. When a worker enters a work station, he uses his work card to register on the RFID data collection terminal of each work station, and the automatic wage settlement system corresponds the work number of the worker to the process performed.
3. Garment pieces with tie
The tying workers in the sewing workshop go to the cutting department to pick up the cut pieces, and deliver them to the designated stations for processing in accordance with the order of the procedures;
After the processing is completed, the tying worker takes back the semi-finished garment pieces, and uses the electronic binding card issuing program to tie the garment pieces that will be stitched together in the next process according to the processing needs. There are three ways to achieve this step:
The tie-up worker reads the tie-up number on the paper label bound on the garment, and manually tie-up;
After the binder uses a handheld reader to read the binding number on a bundle of garment pieces, the binding program records this number, and the binder uses the reader to scan the electronic binding plates of other garment pieces. If the binding numbers are the same, it will automatically hint;
Use a special tying suite: the tying worker scans the first group of garment pieces and then binds a dedicated indicator light on the garment pieces in the scanning order, and then scans another group of garment pieces, when the binding number on the garment piece is the same as the first group of certain bundles When the tie numbers of the pieces are the same, the indicator light on the bundle of garment pieces will be on, so that the dressing worker can manually match the pieces of the same tie number together. This semi-manual method can reduce the need for workers to concentrate, reduce errors, and speed up operations.
4. Process tracking
When the worker is on duty, the employment card is registered on the data collection terminal on the workstation;
The tie-up worker sends the tie-up pieces to the designated station. The worker scans the electronic tie-plates on the pieces on the data collection terminal. The collection terminal prompts the start of the operation. The system records the start time of the process and records it here. Work card for station registration. After finishing all the garment pieces of this procedure, the worker presses the finish button on the reading head, and the system records the completion time of the procedure and the workload of the worker at the same time.
Repeat step 4-ii until the tie-up worker is required to update the tie-up information or all processes are completed (the tie-up is also a process, but it is not reflected in the production plan as a process).
5. Bind card recycling
In the production process, when two bundles of semi-finished garment pieces are about to be sewn into a whole, two electronic bindings will appear. At this time, one of them should be recovered and the content of the next process should be written to the other electronic binding. This recycling work is completed by the tie-in workers during the tie-in process.
After the tying worker retrieves the semi-finished garment pieces from the station where the operation has been completed, the electronic tying plate is scanned in the electronic tying plate issuance program. After the necessary electronic tying plate of the previous process has been scanned, the next process The binding content of the tying card is generated. At this time, the tying worker can write the new tying card content into any electronic tying card and tie it together with the garment pieces to be sewn in the next process.
The remaining electronic tie cards are cleared of content and recycled for reuse. (How to visually distinguish between tie cards in use and empty tie cards? How to combine tie cards with printed labels?)
System layout
Data utilization
The raw data collected by this system is the position and time of the garment pieces and semi-finished products staying on the production line. By processing the original data, you can obtain a wealth of production management and statistical data, including the operating time of each process, the offline time and location of the raw materials, the total workload of the workers, and the cumulative time of each worker operating a process, etc. .
Analyzing these data, you can generate a variety of intuitive reports or charts:
Current production progress
Analysis of working hours of each process and analysis of bottleneck processes
Daily production quantity, production income, production hours
Real-time statistics of worker workload
Real-time productivity analysis
Cycle productivity analysis
And so on, can be customized according to customer needs
In summary, the production line data real-time collection system can perform the following functions:
Real-time information collection: The RFID-based production information integration system uses electronic binding and rfid data collection terminals to collect any event that occurs on the assembly line. Relevant data can be confirmed at the same time the incident occurs. Real-time information ensures efficient management and control.
Production line balance: By quickly responding to the bottleneck of the production line detected online, the production schedule can be adjusted in time to obtain an efficient return.
Order completion progress: The latest order execution status of each production line can be collected and summarized, so as to provide real-time information about the production status.
Quality management: The system stores and displays the work records of different operating employees, and monitors the operator’s operating errors and efficiency in real time online
Remote monitoring: Through the WAN connection, the head office can view the real-time production information of each branch in the headquarters office at any time, supporting mobile management and distributed management.
Salary settlement: The real-time transparency of online operations and salary calculations helps to motivate operators.
Cost control: It can monitor overtime requirements and eliminate calculation errors.
Efficiency control: By tracking and analyzing the operation process time, a better efficiency goal can be formulated.
Worker skill database: establish a skill database of all employees.
Tracking of processed parts: Provide information about finished and semi-finished products that are being processed.
Implementation benefits: The implementation of a production line data real-time collection system can help production companies improve production efficiency. Clothing companies that have already used similar systems have concluded that the overall efficiency of the system has increased by 10% to 25% after the implementation of the system. With real and accurate production line data, production managers can monitor production status more accurately, immediately obtain production efficiency analysis data, and respond quickly to changes, and can predict possible events in advance and adjust production layout in time; With real-time production status reports and charts, business managers can closely monitor and control all work progress without having to be in the factory, and can obtain the necessary decision support basis at any time. The implementation of this system can also greatly improve the efficiency and accuracy of workers’ wage settlement, and help the factory to make more scientific and reasonable pricing of each process, and it can also be traced back to the operator of the defective process.
Please contact for detailed plan
Zhengzhou Lingrui Electronic Technology Co., Ltd.
Address: No. 30, Unit 3, Building 17, Huibao Garden, No. 18, Dongfeng Road, Zhengzhou City
Phone: 0371—63659580 63659581 63506331 63506338
Fax: extension 888
URL:
WWW.LRZZ.NET
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