RFID and Textile Industry-Malden Mills uses EMS products for quality control
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Applied to:
Textile manufacturer
Products of EMS company used
ES650HT Tag
RS427-04 read-write controller
At 3:00 in the silent middle of the night, the roar of the machine gun gradually subsided, and Mr. Simmons tried to curl up his body but still couldn’t resist the severe cold. In this dark and cold night, only the dim light from the soldier’s cigar flickered. Private Salvador Simmons took a deep breath. The cold air rushed into the lungs, paralyzing the entire throat. Perhaps most people who come to Afghanistan are not for the mild climate here, Mr. Simmons said to himself mockingly. Compared with the cold air, his body is too warm, and he keeps radiating warm air from the seated position. Taking off his gloves, he squeezed his hands into the bottom of his sweater. Ahaha, he smiled, it’s really happy.
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Is it a new fashion trend to use plastic bottles as raw materials to make a full set of clothing? Before you think this is ridiculous, it is best to look carefully at the label part of the winter coat in your closet. Malden Mills, a textile company in Massachusetts, is mainly engaged in the design and manufacture of Polartec and ordinary cloth materials. Malden Mills sells stretch textiles to its business partners such as Nike, LL bean and The North Face. Malden Mills has won praise from the U.S. military for its high-quality products and good reputation, and recently won an order from the military.
Polartec cloth equipment front line
When the produced uniforms were shipped to Afghanistan and distributed to soldiers, the military procurement staff of Uncle Sam greatly appreciated the uniforms made of Polartec material. The military needs to make military uniforms that can remain comfortable under harsh conditions such as severe cold and heat, and should not be too cumbersome to wear. Military uniforms made of Polartec material can meet the military’s requirements. It has good breathability, lightness, water resistance and The insulation performance is good, and the raw materials for Polartec textile fabrics are all melted and woven from recycled plastic bottles.
RFID identification for unqualified products
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The production of Polartec textile fabric requires a circular knitting machine to sew 1,700 stitches (see Fig1). The circular knitting machine spins at a rate of 25 yards per minute, and the textile fabric shaped like Christmas stockings can be woven up to 40 yards in length. . The biggest difficulty in the weaving process occurred at the very beginning. The 1,700 needles of the circular knitting machine will inevitably have one or two broken or bent during the high-speed sewing process. If one needle is broken or bent, it will be unqualified. The production of textile cloth.
The woven fabric woven into large rolls is finally cut into pieces, and the woven fabric rolls are separated before being sent to the inspection and sewing station. The reason for the separation is to facilitate the inspection of whether the product is qualified and can be cut into other shapes.
When the textile fabric is dyed, it passes the inspection site and is sent to the segmentation site. The dividing machine divides the rolled cloth into different shapes. If a nonconforming product is found at the inspection site, the operator will tie a knot at the defective place, and then the knot tied at the segmentation site will be detected, and the operator will manually handle the defective place. Such a process has proved to be very unreliable and expensive to run in practice. In order for the detection device to find the knot, the operator had to improve the way the knot was tied. If the knot made by the operator is unqualified, the system will not be able to correctly identify the defective place, which creates a serious hidden danger. A defective place may cause damage to the segmentation machine. In turn, high machine maintenance costs and serious waste of textile fabrics were generated. In order to effectively avoid the occurrence of the above incidents, Malden Mills decided to update their quality control system. After demonstration, the RFID system of the EMS company was introduced. After the implementation of the system, the occurrence of defective products was greatly reduced and huge economic benefits were produced.
Shaun Sullivan, head of engineering at Malden Mills, once asked Kevin, an engineer at General Machine, about RFID. Kevin gave him some information about RFID technology. When the company was preparing for a new identification system, he consulted Kevin and asked him whether the RFID system could solve the problems he faced. The answer is yes. At the same time, Kevin recommended the read-only code carrier ES650HT of an EMS company focusing on the RFID field.
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The EMS series code carriers are used in pairs at the product inspection site. When a roll of cloth is transported to the inspection station, the operator takes two code carriers, one at the head end and the other at the end, and the code carrier is sewn on It is kept in a small packaging bag until it reaches the drying and cutting station.
EMS company’s RS427-04 transmission belt reader antenna is installed at the entrance of the drying and cutting station. These reader controller antennas are specially designed for ordinary conveyor belts and can be installed between two conveyor rollers. Once the code carrier passes through the read-write range of the reader, the RS427-04 reader reads and writes the code carrier information. Malden Mills currently has two sets of readers installed to read and write more than 300 code carriers.
When a huge textile fabric is produced, it is sent to the cutting workstation. The RS427-04 reader reads the existence of the code carrier and transmits it to the PLC of AB, and then the PLC sends a stop command to the cutting machine. The operator finds the initial code carrier, and then rotates the cutting blade to start cutting. There is no waste in the cutting process. Finally, the operator takes out the code carrier and stores it for next use.
The Sullivan team believes that RFID is a very helpful technology for the company. Since the use of the RFID system, it has significantly reduced the waste of raw materials and effectively reduced the defective rate of products. Malden Mill’s successful application of the EMS company’s RFID system shows that the application of RFID data collection systems in the manufacturing supply chain can effectively save costs and time.
EMS Radio Frequency Technology China Service Center
Phone: 010-88430403fax: 010-88447190
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