How does the apparel industry use RFID to achieve efficiency indicators?
chrispeng [ad_1]
RFID production management solutions provided by Zymmetry Group for the apparel industry
The Zymmetry RFID production management solution (ZymFactory) uses radio frequency identification technology to obtain real-time production information and worker efficiency through the production process. It provides a complete solution for the factory and helps supervisors to obtain it from the system platform. Data, so as to balance each production line in real time and monitor it in real time. At the same time, it also provides a series of tools to help managers analyze and make objective decisions from different perspectives.
The uniqueness of ZymFactory-RFID production management solution is mainly reflected in the following aspects-
Real-time monitoring of production bottlenecks
Save salary
Reduce defects
Precise calculation of capacity and production cycle
Reduce manpower errors and automatically import salary data
Optimize production management process
Since the end of 2006, Zymmetry Group has successfully implemented RFID production management solutions for more than 100 factories, and more than 100,000 workers use RFID systems online. Most of them are medium-sized enterprises that are in urgent need of development, especially some Hong Kong garment enterprises that have processing plants in the Mainland. In addition, some foreign garment factories in Sri Lanka, the Philippines, Thailand, Vietnam, Cambodia, and India have also decided to adopt this program.
At present, many garment factories of different product categories around the world have successfully implemented the ZymFactory-RFID production management program, including woven, knitted, underwear, wool, swimwear, jackets, handbags, shoes, etc. One of the most praised by customers is that the use of the system will not change the original operating mode. A recent survey conducted by the Zymmetry (思明启域) group showed that most of the factories that implemented the system management have greatly saved labor and raw material costs due to the increase in productivity and operational efficiency, and obtained the cost within six months. Return on investment. Mr. Cheng Tong, CEO of Zymmetry Group, pointed out: “The solution can reduce operating costs by reducing the number of program errors and product defects. This can increase the productivity of the plant site by up to 30% and save up to 8% in cost.”
Why does the clothing industry need RFID?
As far as the industry is concerned, due to the complexity and particularity of the apparel industry’s supply chain, there are many thorny problems in each link, and the traditional production workshop management lacks breakthrough solutions. The information communication of the factory workshop is just like “Information Black Hole”. Zymmetry Group, a provider of RFID solutions for the apparel industry, in order to make the industry more aware of RFID and its current applications in the apparel industry, and accelerate its application process, the following is a discussion of the projects provided by Zymmetry.
With the implementation of the globalization of the manufacturing industry, the multi-factory supply chain (Multi-factory Supply Chains) model of the “multi-factory production” plan has also emerged. When imagine that multiple production planning supply chains are carrying out the production of the same batch of goods, it is likely that data and data like mountains and seas are being exchanged, provided, collected at the same time…
The clothing industry has always been pursuing product trends and production efficiency, and computer technology has also been the driving force for the development of new efficiency production and management for many years. At the same time that manufacturers are making progress and gaining benefits today, their attention has also turned to a variety of network tools; from RFID for complex inventory control and supply chain management functions to B2B e-commerce transactions. However, before using some of these new technologies, manufacturers must face a long-standing problem: the comprehensiveness and practicality of the new technology in business operations.
Zymmetry analyzes common confusion problems in the workshop:
-General workers in the workshop often have the habit of storing work tickets. This omission not only increases overtime costs, but also affects the factory’s inability to accurately grasp the output of workers.
-Low production efficiency is mainly due to the lack of strict quantification in management, lack of planning in production, low equipment utilization, and non-coordination of personnel arrangements.
-Supervision is out of control. When there is a delay in production, an early warning notification is not issued in a short time. The uneven performance of the employees in the production line lacks data measurement, which seriously affects the production progress.
-Lack of data for operational analysis. At present, many factories have used various types of computerized technology networks to control production operations, and these computer program modules support a variety of proprietary settings. In addition to increasing maintenance costs, this situation has also become difficult to collect data for enterprise planning (real-time statistical data in the production process).
Therefore, a comprehensive enterprise information management planning system, such as the Zymmetry R&D department specializing in WIP production process RFID technology-RFID production management program, combined with Zymmetry clothing industry ERP solution, is a silver bullet for the enterprise.
Introduction to ZYMMETRY’s use of RFID technology in workshop management
The traditional production line’s Feizi operation is compared with Zymmetry’s use of RFID record cards in the WIP process flow: instead of the paper-printed work ticket (Feizi) of the production line.
It is difficult for general management to use the “work ticket flying boy” as a tool to understand and track the production progress. Workers will not only save the flying boy before handing it over before the grain period (or transfer it to false wage reports when working overtime), and increase the amount of grain calculation. In addition to processing and cost, the actual progress of production will also be confused. The RFID system provided by Zymmetry uses the pre-set production data of each component to be stored in the RFID system, and the RFID record card is used for the production process management in the WIP process flow. When the RFID production card passes through the reader in front of each trolley or production machine, the start and end of each process can be transmitted to the main server database in real time. The program will automatically calculate and count the production progress and piece rate to achieve “real-time production” The comprehensive tracking control of “management process” provides a large amount of analyzable data for production department balance, worker output value, equipment utilization rate, etc.
Through the computer, Zymmetry transmits the real-time production process to managers at all levels, greatly improving transparency.
How to implement the recording, transmission and management of real-time information in factory production will be discussed in detail at the implementation plan level.
Zymmetry (思明启域) group-RFID production management solution
ZymFactory-RFID production management program, application production categories include woven, knitted, underwear, wool, swimwear, jackets, handbags, shoes, etc. One of the most praised by customers is that the use of the system will not change the original operating mode. At present, most of the production modes of garment factories in China and Hong Kong are based on Bundle Production Mode or Unit Production Mode. The biggest disadvantage of this streamlined production line model is that there is often a backlog of semi-finished products/work-in-process (WIP), such as complicated processes and a long production process, which weakens the manufacturer’s ability to predict, control and respond to the production cycle. The traditional production management model has become increasingly difficult to cope with market requirements that require rapid response and extremely short delivery times. The RFID production management solution provided by Zymmetry Group for the apparel industry-ZymFactory, is definitely aimed at this problem. For IT solutions. Simply put, the RFID production management solution is to add RFID technology to the integration process of different pieces of clothing, and systematically track the progress of processing and production in each production line. Different from the management methods of general production lines, RFID production management solutions are not hindered by the complexity of different production areas and styles that hinder the tracking of “real-time” production data.
Real-time is one of the advantages of this system-the RFID production management solution provides “real-time data” on the production line. Good management emphasizes balanced production and encourages overall operations, not purely pursuing individual output. The transfer of semi-finished products between processes and processes is very close, because any obstruction will directly affect the operation of other processes in production, so the overall production of workers and mechanical capacity arrangements are based on the principle of smooth production processes. In addition, the management itself must strictly limit the inventory of semi-products. Based on the short-distance design of the production system and the principle of simultaneous production, the storage of semi-products will not be large at all. These restrictions and rules need to be digitized, standardized, and Computerized.
Many Hong Kong-owned garment factories have successfully adopted RFID production management solutions. One of them is a Hong Kong-owned garment factory in Zhongshan (Xiande Industrial). When asked about the secrets of using RFID production management solutions, the factory was responsible People say that balancing the flow of water is very important. To achieve a balanced flow of operations, you must first have a proper production plan and manpower arrangements. In conjunction with the Zymmetry system, the factory’s production line engineering team will conduct process analysis and time research on the order styles before production, and formulate a production plan, including process time, daily estimated production volume, and mechanical equipment layout drawing into the system. These Production data is also the production index of the cutting department. The backlog of cut pieces is also reduced by the production method. The management emphasizes that the RFID production management plan can make the production process digital and computerized, so that past problems can be “understood.” . Only on the system monitoring screen, managers can use visual management calmly, discover and solve production problems in a short time, greatly reducing the possibility of problem backlogs. If necessary, deployment revisions can be made at any time during production to reduce the problem of unbalanced production lines, and overall productivity can be improved while costs can be relatively reduced. In general, the RFID production management solution solves the problems of the traditional production mode of semi-finished products, difficult quality control, and long production cycles. In today’s clothing market with meager profits, diversified customer requirements, and fierce competition, these common problems are often fatal. For the clothing industry, we should learn from them.
RFID plays a role and integrates the tight links of the global supply chain
Although RFID has a wide range of applications, it is even more ubiquitous. It further combines digital homes, Internet, wireless networks and equipment to develop remote care, security monitoring, digital entertainment, vehicle navigation, electronic containers, medical waste tracking, and airport luggage. The use of new integrated technologies such as customs clearance creates unlimited business opportunities. However, Zymmetry consultants believe that clothing companies can obtain greater benefits from RFID technology, and the focus should be on real-time data in the supply chain. RFID will have a huge impact on all aspects of supply chain management. It can record from basic process work to the most complex analysis work, manage gigabit data, collect information in real time, and so on.
Zymmetry’s RFID production management solution: people/things/events are tracked, and real-time data collection is synchronized.
From the perspective of the integrated supply chain (Integrated Supply Chain), the RFID system greatly improves the transparency of each link of the supply chain (different supply chain projects in different regions), and items (including processes) can be tracked in real time anywhere in the supply chain. In terms of the depth and breadth of supply chain integration, integration can be divided into four levels: more accurate information integration, more effective synchronization plans, more effective collaborative workflows, and comprehensive supply chain integration. RFID makes revolutionary changes at every level, truly realizing real-time supply chain integration.
Zymmetry consultants pointed out that RFID technology optimizes the integrated supply chain environment and provides a new business operation mode for supply chain participants, enabling enterprises to pursue their goals more effectively.
Real-time information. RFID does not require human hands to identify the tag, the reader directly reads the relevant data (employee card, process card) in the smart card from the radio frequency tag. Some card readers can read the data of one or two hundred labels in a very short time, which is a thousand times faster than the traditional scanning method, saving a lot of labor resources (only relying on manual processing). Take production line management as an example. In a supply chain environment with a well-integrated RFID WIP and ERP system, due to the high degree of information sharing, process progress information is placed in the information flow of the entire system and can be queried in real time by all participants and managers , The stored data can be used for wage calculation purposes, further reducing manpower and errors.
Secondly, the RFID system can effectively promote the supporting enhancement of the supply chain (including the ERP system). In a highly coordinated and integrated environment, information flow can cooperate with logistics and capital flow to achieve more flexible business processing, but it is even more critical to effectively link information flow with related businesses. RFID technology is implemented through an ERP system across departments (and even across different cooperative partners). Upstream suppliers and manufacturers and downstream distributors and retailers can track and obtain first-hand information during production progress, thereby reducing inventory In order to reduce the occupation of mobile data, materials and products can be stored more accurately and efficiently.
Furthermore, real-time supply chain management is truly achieved. Comprehensive global supply chain integration is like a large-scale virtual enterprise organization. Each member of the organization shares information, synchronizes plans, and uses coordinated business processing procedures to cope with the complex and changing market and provide end customers with efficient, fast, and efficient Flexible business, gain advantages from it. Through the information system platform integrated with Zymmetry’s RFID production management solution, the production line and process can be clearly and accurately displayed in any situation. Each supply chain participant can gain insight into the status of the entire supply chain and make the entire supply chain react. Speed and accuracy are greatly improved.
What benefits does technology bring to the industry?
More accurate and real-time data collection and tracking:
The Zymmetry application can be configured with the advent of wireless technology. By using a computer system for data transfer, it replaces the traditional paper data system used from material inventory to the production line, enabling the industry to reduce administrative costs and speed up operational response. At the same time, RFID is used in the management control of manufacturing management systems such as material control, production WIP process progress, order tracking, inventory, logistics, sales data, and related security, which strengthens the overall efficiency. When RFID wireless technology enters the climax of development and gradually replaces Bar Code, the future development prospects will have even greater changes. However, even now, wireless technology is revolutionizing factory floors and warehouses.
In addition, in terms of employee attendance clocking in:
When company employees go to work, they use RFID (Worker ID Card) instead of punch cards. The computer system can record working hours and is connected with the company’s salary and accounting system, thus speeding up the processing of salary calculation and other human resource management tasks. It is more in line with the customer’s factory compliance requirements: employee RFID cards can be applied to employee identification, work records, employee salaries, etc., giving the industry more advantages.
With regard to efficiency improvements, RFID greatly reduces costs and saves time: Radio frequency identification technology has become an economically feasible solution. In addition to implementing this solution across the entire supply chain (from the place of production of the goods, after storage, selection and packaging, , Throughout logistics, cross-border transportation and shipment, until the completion of inventory control and retail work), but also can be used in the entire or different stages of the production line. The more RFID tags are used, the more real-time information about the current production status can be obtained, including raw material storage stages, employee performance (save unnecessary additional salary payments and save a lot of administrative expenses for handling human resources), each The output of the production stage until the final grasp of the real-time inventory level. Another important aspect is environmental protection. Because RFID cards can be recycled and reused, paper waste for printing work tickets can be completely eliminated!
Strengthen good contact with buyers and customers:
No matter whether RFID technology is applied in production, information, logistics and transportation in the Mainland, Hong Kong, or even overseas buyers and customers, it will be used in the advanced technology of providing information for the manufacturing industry, using RFID sensing and response (sense-and- respond) Contact the environment, provide faster and more data reports for partners in many aspects, combined with good and close cooperation, the industry can use this to obtain more benefits from the use of enterprise resource planning and management application systems.
Zymmetry understands the importance of accurate data analysis to business management. RFID is an identification technology that uses radio waves to transmit messages. A complete set of radio frequency identification systems is composed of RFID tags and sensors (RFID Reader), which mainly use RF radio signals to transmit wirelessly. Data is distinguished, tracked, and managed through ID recognition. This method can actually reduce human errors during data collection. Through the cooperation of RFID tags and sensors, the manufacturing industry can update the production line progress information, monitored production quantity, mechanical configuration, and employee work dynamics in real time for deployment as needed, and achieve the consistency of planning and execution timeliness.
R&D and innovation, tracking all links of the clothing supply chain
In order to focus on and cooperate with the complexity and particularity of the apparel industry’s supply chain, the RFID system is not only tracked in the cutting bed, film room, workshop, ironing department, packaging, etc., but Zymmetry’s development and research department has more washing processes. Self-developed high-temperature resistant RFID tags, unique openings and thick body design can prevent the tags from falling off when the washing machine is in operation and do not damage clothing materials, so it is the selling point of the new type of tags.
Application examples, the efficiency index is immediate
As a large-scale underwear manufacturer in Asia, Hong Kong Yintak has more than 1,000 workers and an annual output of more than 100 million pieces, which are exported to major clothing retailers in Europe, America and Australia, such as Wal-Mart.
In a garment factory, the management of workers and the supervision of production schedules are not an easy task. As far as wage management is concerned, in order to encourage workers to work more and earn more, clothing companies generally adopt the method of piece-based wages. However, the relevant labor laws and the social responsibility standards required by customers also include minimum wages and overtime wages. Therefore, workers The calculation of wages requires multiple considerations and overall planning.
Before adopting Zymmetry’s RFID technology, Xiande, like other garment factories, used work cut tickets to calculate wages. After the worker completes a certain process of a bundle of semi-manufactured products, he cuts down the corresponding work ticket as a proof of workload statistics, and then a special person collects it on time and calculates the salary.
However, it is impossible to accurately grasp the working status and efficiency of each worker. More importantly, it is impossible to quickly and accurately grasp the production schedule, and it is time-consuming and laborious. Some workers even keep their work tickets for normal shifts in order to get more wages. It was not paid until the overtime day, which virtually increased labor costs.
With the advent of the era of global integration in the international apparel market and the increasingly fierce competition, the market demand for small batches, multiple varieties, and short delivery times has become increasingly prominent. It is obvious that low-efficiency, high-cost, and labor-intensive clothing factories can no longer meet the demand. .
The RFID production management solution uses the employee card and the number card to accurately reflect the worker’s working status and production line production status to the computer system in real time, so that the manager can grasp the production schedule in time. Accurate calculation of production capacity and production cycle through data information, timely detection of production bottlenecks, and help managers optimize production management processes and improve production capacity.
In addition, the program automatically collects production data, replaces traditional work tickets, automatically calculates wages, effectively supervises workers, strengthens workers’ sense of responsibility, and makes management more standardized.
Xiande said that after applying Zymmetry’s RFID management solution, employees’ overtime expenses have been reduced by 15%, time spent on order follow-up and administrative management has been saved by 20%, overall productivity has been directly improved, production cycle has been shortened by 18%, and all aspects of operation Performance indicators have also improved by 15-25%.
About Zymmetry Group
Zymmetry Group (Zymmetry Group) was established in 1989 as Zymmetry Co., Ltd., and has now become a leading global supplier of procurement and manufacturing solutions for the apparel industry. Siming Qiyu Group is headquartered in Hong Kong and has offices in the United States and China. Its customers include world brands in the United States and even large-scale global manufacturers in Asia.
According to Mr. Tong Cheng, CEO of Zymmetry Group, Zymmetry is currently the first domestic supplier to provide this solution. After more than a year of market launch, the company’s patented RFID solution has received good feedback from the market. Since the launch of the program, 100 factories and more than 100,000 users have adopted this system online, most of which are medium-sized enterprises in urgent need of development, especially some Hong Kong garment enterprises with processing plants in the Mainland. In addition, some foreign garment factories in Sri Lanka, the Philippines, Thailand, Vietnam, Cambodia, and India have also decided to adopt this program.
For more details, please visit http://www.zymmetry.com. Or call: +852-2588-1848,
Fax: +852-2583-9825 for contact and inquiries.
[ad_2]
