Production line management system for automobile manufacturing enterprises based on RFID
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Introduction to RFID system
RFID is a non-contact automatic identification technology. It uses radio frequency signals to automatically identify target objects and obtain relevant data. The identification work does not require human intervention. The RFID application system has a series of advantages such as non-contact, long working distance, high accuracy, automatic and fast information collection and processing, and good environmental adaptability. It can not only replace the traditional manual entry method, but greatly improve the operating efficiency of the enterprise. Its advanced automatic The recognition function can easily realize tasks that were previously difficult to complete manually, and provide strong support for improving the competitive advantage of the enterprise and enhancing the core competitiveness of the enterprise.
An electronic tag generally stores electronic data in an agreed format. In practical applications, the electronic tag is attached to the surface of the object to be identified. The reader can read and identify the electronic data stored in the electronic tag without contact, so as to achieve the purpose of automatically identifying the object. Usually the reader is connected to the computer, and the read tag information is transferred to the computer for further processing. The RFID information processing system (ie, back-end application support software) integrates the tag data collected by the reader.
Status and needs analysis
Situation Analysis
The company’s bus factory is divided into four workshops: welding, painting, final assembly, and completion inspection, with a workshop area of about 15,000 square meters. At present, the collection of production line information adopts manual collection and manual input. The accuracy of manual collection and manual input is insufficient, and there is a certain error rate. Manual input can only be done regularly, resulting in the production plan being submitted on a weekly or monthly basis, which cannot be accurate to the daily quantity.
The production data in the system cannot be updated in real time, and the lag situation is serious, which is not conducive to the smooth progress of the production flow and restricts the further increase of production capacity.
demand analysis
Based on the above analysis of the current situation, our company proposes the following RFID solutions:
1000 high temperature resistant, anti-corrosion RFID anti-metal tags (made into recyclable form) are used for one-to-one identification management of vehicles on the production line of each workshop. Before performing each batch of production tasks, you need to initialize the information of each tag with the electronic tag issuer in the production line management system. The information corresponding to the tag should include: production line code, product code, order number, status location, plan number, product sequence Number, VIN information, etc.
The label is fixed on the vehicle on the production line with rivets or other methods. After the vehicle has passed the inspection process, the label can be removed for reuse next time.
A UHF RFID reader is set up at the welding upper line point, outer Mongolia upper line point, and welding lower line point of the welding workshop to collect information from vehicles entering the production line of the welding workshop, and pass the information through the Ethernet Real-time return to the background management system.
Set up an UHF RFID reader at the paint line up point and paint line down point of the paint shop to collect information on vehicles entering the production line of the paint shop, and send the information back in real time via the Ethernet network To the background management system.
Set up a UHF RFID reader at the final assembly line point, final assembly line point, and cross-check point of the final assembly shop to collect information on vehicles entering the paint shop production line and transmit the information back in real time via the Ethernet network. To the background management system.
A UHF RFID reader is set up at the qualified point of the inspection workshop to collect information from vehicles entering the inspection workshop and transmit the information back to the back-end management system in real time via the Ethernet network. The RFID production management system needs to interface with the existing ERP system.
System composition and principle
System composition
The RFID production line management system (MES) is mainly composed of a basic hardware network platform, a hardware interface platform, a management software platform, and an ERP system interface platform, as shown in Figure 1.
Figure 1 RFID production line management system composition structure diagram
Basic hardware network platform: the data transmission network between the on-site information collection point reader device and its back-end management system.
Hardware interface platform: the part responsible for hardware control management and hardware data collection in MES software.
Management software platform: MES software is responsible for all business processing related to production execution management, which is the core part of the MES system.
ERP system interface platform: the part of the MES software that is responsible for data exchange with the ERP system.
System principle
As shown in Figure 2, in the welding shop’s welding up-line point, outer Mongolia up-line point, and welding down-line point, paint up-line point and paint down-line point in the paint shop, final assembly up-line point and final assembly line down point in the assembly shop An UHF RFID reader is installed at the inspection point, the inspection point, and the qualified point of the inspection workshop, which is used to automatically collect vehicle information on the production line.
Figure 2 Schematic diagram of the principle of RFID production line management system
When a car with an electronic tag passes through the information collection point of the production line, the reader will automatically collect the information of the car’s electronic tag and transmit the information to the background management system in real time. The background management system can realize various managements of the entire production line based on these real-time data.
System functions
Production management
Arrange the production plan according to the production order, including production order import, order statistics and status information turnover, production task decomposition, automatic task assignment, etc.; produce and issue electronic tags according to the production plan; vehicle data collection at the production line collection point of each workshop, and the collected data Data includes: production line code, product code, order number, status location, plan number, product sequence number, VIN information, etc.; the collected field data is transmitted to the background management system in real time, so that all operating information during the production process can be real-time by the system record it.
Statistical Analysis
Through mathematical statistics, mathematical analysis, data mining and other methods, all kinds of data needed by the enterprise are obtained: real-time production line output, process output rate, equipment and personnel operating conditions, etc., automatically generate Plato, histogram, Xbar chart, etc. Class quality reports, charts and reports, and feedback to the online system for performance analysis and improvement, with on-site data reporting and query functions, to provide support for the decision-making of senior management.
System Management
System backup and recovery mechanism; system operation log; operator authority setting; collection terminal configuration and control; ERP system interface rules; data initialization.
Data interface
Obtain engineering data from the existing ERP system, provide WIP information for the MES system, and provide the required data for the existing ERP system
Operating procedures
Figure 3 Operation flow chart
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