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1. Problems in traditional production line management
In traditional manufacturing companies, the collection of production line data information mainly relies on bar code recognition, manual collection, and manual input. Because of manual input, it can only be done at regular intervals. The production plan cannot be accurate to the day. It must be done on a weekly or monthly plan. The data cannot be updated in real time, and there is a serious lag, which makes the production flow unable to proceed smoothly and greatly restricts the production capacity. In addition, because functional departments mostly use paper and pen recording methods, data is prone to errors and low accuracy, which greatly reduces productivity.
Traditional barcode management can no longer meet the needs of solving the following problems.
1) Different efficiency of workers can easily lead to uneven labor in small groups.
2) The production is prone to abnormalities, and the bottleneck of the production line cannot be found in real time.
3) Low labor efficiency and low utilization rate of working hours.
4) Once the barcode is smeared and concealed, it cannot be accurately identified.
5) It is impossible to track and make decisions on the on-site production situation in real time, and it takes a long time to find errors and high costs.
6) The data collection process needs to be arranged by multiple personnel, and the labor cost is high.
RFID technology is a new high-tech technology, which uses wireless for identification, has strong penetrability, long identification distance, fast transmission speed, and has essential advantages that barcodes do not have: long-distance reading and writing, non-visual reading and writing , High-speed mobile reading and writing, large amount of stored information, can be used in harsh environments. With the application of RFID technology in the manufacturing industry, it will change the production and operation mode of enterprises.
2. Application of RFID in production line management
In-love focuses on the field of manufacturing, providing enterprises with professional RFID system integrator solutions, and has developed a production line management system based on RFID technology. RFID technology is applied in the production line, transfer and temporary storage warehouses, and product information is written into tags and bound with the products. Readers are installed at the production line stations and warehouse entrances and exits. The system automatically reads the data and geographic location information in the label, and shares the data with the IT system, displays the information on the display screen, and prompts the production line operator how to operate. By combining with management systems such as ERP, SCM, and MCS, RFID allows every employee of the company to exert maximum effectiveness.
Figure 1-RFID computer production line
1. System introduction
The system mainly includes: card issuance, station management, warehouse management and other processes.
Figure 2-System network structure diagram
1) Card issuance management
Arrange the production plan according to the production order, bind the goods with the RFID tags, obtain product information through the ERP related data interface and write the tags (such as batches, box numbers, etc.), establish product files in the MES system, and automatically track The conversion process of the goods production line.
2) Work station management
RFID readers and antennas are installed at each station. When a product with an RFID tag enters the RFID station, the reader reads the tag data on the product and transmits the information to the logistics control management system, which is based on the product Information, lists the package number, batch and other information of the goods, and displays it on the display screen, prompting the production workers to perform related operations.
Figure 3-Schematic diagram of the layout of the production line readers
3) Warehouse management
After the product goes offline, it is transferred to the warehouse. There is an RFID channel reader in the warehouse, which automatically collects the data of the products in and out of the warehouse, reflects the inventory situation in real time, and realizes the efficient and real-time management of products and goods.
Figure 4-Schematic diagram of warehouse reader layout
The main hardware in the system: YAB13002K UHF anti-metal tag, YAB13004K mini anti-metal tag; YAB23341 UHF high-performance fixed reader, YAB33051 UHF circularly polarized antenna, YAB41101 embedded industrial controller, alarm, Infrared sensor.
Third, the income after the real-time RFID system of the production line
After the real-time RFID production line management system, it will bring the following benefits to the enterprise:
1) Realize real-time and accurate collection of production data.
2) Productivity has been greatly improved.
3) Real-time tracking of order progress to ensure delivery time.
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