The RFID Production Line management system, based on advanced RFID wireless radio frequency identification technology, is applied across the production line, transfer stations, and temporary storage warehouses. It utilizes reusable radio frequency electronic tags, each with a unique ID number and a read-write data area, to store product information. At key points such as the production line’s downline station and warehouse entrances/exits, RFID read-write devices are installed to automatically capture and update tag data. This information is then shared with other IT systems while simultaneously being displayed on monitors to guide production line operators.
By implementing the RFID Production Line system, semi-finished products can be tracked throughout their entire journey—from offlining and warehouse transfer to storage, temporary holding, and eventual reintroduction into production. This ensures accurate batch-to-box number correspondence, minimizes production errors, and records critical process data for future quality traceability.
Antenna RFID Reader | High-Gain RFID Scanning for Precision Tracking & Automation
1. Project Background
In traditional manufacturing enterprises, daily management is more focused on product management, quality management, warehouse management, mobile asset management, field personnel management, fleet management and so on. The collection of production line information is usually done manually. The accuracy of this manual collection and manual input is far from enough, and there is a large error rate. And manual input can only be carried out at regular intervals, resulting in the production plan submitted by weekly and monthly plans, which cannot be accurate to the day. Production data in the system can not be updated in real time, the lag is serious, not conducive to the smooth flow of production, restricting the further improvement of production capacity. At the same time most of the functions of manufacturing companies mostly use paper and pen primary recording methods, which makes most of the functions of manufacturing companies face a large number of data errors, reducing the overall productivity of the enterprise.
Manufacturing companies have realized the existence of these problems and have tried to use emerging technologies to solve these problems. Currently, some manufacturing companies use barcode recognition to improve the accuracy of data entry, but barcode recognition is still a technical bottleneck:
- Workers’ efficiency is different, which can easily cause uneven division of labor in the group;.
- Production anomalies, production line bottlenecks can not be found in real time;.
- Inefficient labor, the actual work time utilization is not high.
- Once the barcode labels are printed unclearly, there are traces of folding and other problems, the barcode gun will be difficult to recognize.
- Can not be tracked in real time, the management is difficult to work according to the state of the work schedule, if the work process of a process problem, to rule out the words must wait until the next day.
- Barcode data collection requires special arrangement of personnel team to operate, labor cost overhead.
Therefore, the barcode identification as a representative of the production line management system has been increasingly unable to meet the requirements of the enterprise for efficient, lean production management, enterprises in the deepening of modern management concepts at the same time, to build a more advanced technology production line management system is of great significance.
2. Project Definition
RFID wireless radio frequency identification technology is both bar code and another cause of change in the field of automatic identification of emerging high-tech technology, the use of wireless electromagnetic wave penetration, long-distance transmission and high-speed data exchange characteristics, through a specific protocol to achieve the marking of the information on the goods automatic identification technology. In the manufacturing industry, relative to the current widely used bar code technology, UHF UHF RFID technology has the essential advantages: wireless long-distance reading and writing, penetrating reading and writing, can be read and written in the state of high-speed movement, storage of more data, can be used in harsh environments and so on. Therefore, RFID technology is not just a simple replacement of bar code technology, its application in the manufacturing industry will change the way of production and operation of enterprises.
Alien ALN-9662 Short RFID White WET Inlay – High-Performance UHF RFID for Asset Tracking
Constructs the production line management system based on the UHF ultra-high frequency RFID technology, is takes the computer network as the foundation, takes the RFID as the core, the construction conforms to the enterprise production management request, solves the enterprise existing question as the goal, from the production line semi-finished product to come off the line, the warehouse transfers the storage and the temporary storage, then goes on line the production and so on the whole process carries on the automatic real-time data collection, carries on the tracking management to the goods batch box number the synthesis management system.
The electronic label as the data carrier, can play the mark recognition, the article tracking, the information collection role. The electronic label, the read-write, the antenna and the application software constitute the RFID system directly with the corresponding management information system connection. Each item can be accurately tracked, this comprehensive information management system can bring many benefits for customers, including real-time data collection and tracking management, therefore, RFID technology applied to the production line between the goods conversion tracking management, can effectively prevent errors, realize the production line logistics management intelligence, significantly improve the enterprise production line management level.
3. System design
Based on RFID technology production line management system, in the production line, transfer and temporary storage warehouse application of advanced RFID wireless radio frequency identification technology, the use of reusable radio frequency electronic tags, each tag has a unique ID number, as well as read-write data area, the product information written in the RFID tags, in the production line down the line station and warehouse entrance and exit installation of read-write, by reading and writing the tag information automatically Write and collect each position product information, and share the data information with other IT system, the information at the same time show in the display, prompt to the production line operator, so as to semi-finished products from the line to the warehouse to transfer to the storage, temporary storage, and then on-line production for the whole process of tracking and management, so that you can ensure that the production line of goods between the batch of the box number of the correspondence of the production line can be completed without error production tasks, and record production of important information in the process. Important information in the production process can be recorded, which can provide basic data service for future quality information tracing.
3.1 Construction Objective
Manufacturing production line enterprises to introduce RFID, RFID and existing IT systems combined to establish a real-time production line management system, more optimal and rational use of resources, improve production capacity, improve asset utilization and a higher level of quality control and a variety of online measurement to create greater benefits for the enterprise.
RFID provides constantly updated real-time data flow. Complementing manufacturing execution systems, RFID provides information that can be used to ensure the correct use of labor, machines, tools and components, resulting in paperless production and reduced downtime. Further, as materials, parts and assemblies pass through the production line, the process can be controlled, modified and even reorganized in real time to ensure reliability and high quality. All data is wirelessly captured at high speed by the client PC.
With real-time data flow as a basis, ERP and other management systems can mine these large amounts of data, the production schedule, the process of real-time effective supervision, to identify production bottlenecks, to solve production problems, the deployment of a higher level of quality control and a variety of online measurement.
RFID can provide the most accurate calculation results of the working hours required for the process, ERP software can be used to accurately assess the working hours of each worker for each process through RFID, calculate the actual production capacity of each production line, enterprise managers can use these data to make more accurate analysis of the enterprise’s business capacity.
Completion of data mining, analysis, enterprise management personnel to master the workshop production capacity, immediate solution to production bottlenecks, real-time supervision of production progress, through quality monitoring to improve the production process, RFID for the enterprise to achieve a balanced production line to provide the basis for the enterprise ERP, SCM, MCS and other mainstream management systems, so that every employee within the enterprise to play the maximum energy efficiency.
3.2 System network diagram
The network diagram of this system is as follows:
The system mainly realizes the intelligent management of the whole production line from card issuance to workstation management and warehouse management.
3.3 System flow
3.3.1 Card issuance management
Arranges the production plan according to the production order, including production order import, order statistics and condition information dumping, production task decomposition, task automatic assignment, etc., makes and issues the electronic label according to the production plan, binds the electronic label with the goods that need to be managed, and obtains the product related information through the ERP sharing interface, and writes the information in the electronic label such as the batch, box number, etc., and establishes the product file in the production management system. Establish product files and fully automatic tracking of goods production line conversion process.
Long Distance RFID Reader Built in 12 dBi Antenna
3.3.2 Workstation management
In each workstation Department RFID read-write and antenna, when the goods installed with RFID tags into the RFID work point, read (write) device that reads the product on the electronic tag stored data information; read (write) device read electronic data information directly transmitted to the logistics control management information system, management system and then according to the product production information, listed in the package number of the goods, batch information, shown in the display On the display, prompting production workers to carry out the correct operation.
Passive RFID Reader Integrated with Impinj E710
4. The system benefits
Based on the completion of RFID technology production line management system, can bring the following benefits for the enterprise:
4.1 Production data can be accurate, real-time collection.
Real-time feedback of production data is to ensure that the basis of smooth production operations. System in the production workshop to collect real-time production data is RFID equipment real-time automatic collection, impinj RFID read-write by reading out the goods RFID tags with specific information in real-time feedback to the system, the server and every 5 seconds to update the data. Through this way of operation system can provide real-time production data for collection and data analysis.
4.2 Productivity on the basis of the original realization of the promotion
Productivity is the hotspot of production management is also the management of the difficulty, if you improve the productivity means that the enterprise’s output increased, profits can be increased. Production workshop real-time production data feedback to the system, through the system monitoring can be found in real time to impede the smooth flow of the production line where the reason is, and timely discovery of production bottlenecks. The system is through real-time data aggregation of each workshop, each group, each workstation production situation for real-time monitoring, so that you can find any production link appears abnormal state, and timely solution to the bottleneck hindering the production flow. Overall, it guarantees the smooth flow of the assembly line and improves productivity.
4.3 Real-time tracking of order progress to ensure timely delivery
If the order can not be delivered in time means that the company not only can not make a profit but also lead to a loss, but also affect the credibility of the company. The future development of the company is greatly affected and hindered. Especially export enterprises for the timely delivery of orders is more important. The system is based on customer orders to start, to be produced from the beginning to the end of the production process of the entire production process of real-time progress tracking. Real-time tracking orders in the production line progress, so as to accurately grasp the production progress of each order, to achieve the purpose of timely delivery.
5. Conclusion
Based on RFID technology production line management system through advanced wireless radio frequency identification technology, realizes the whole process automation tracking and management from semi-finished products off the line, warehousing and transferring to then on-line production. The system takes the reusable electronic tag as the carrier, combines the read-write equipment and information system, effectively solves the problems of low efficiency of manual entry, data lag and barcode recognition bottleneck in the traditional manufacturing industry. Through real-time collection of production data, monitoring the progress of orders, optimizing the allocation of resources, the system significantly improves the production efficiency and management accuracy, and provides reliable data support for the lean production and quality traceability of enterprises.
The application of the system not only reduces labor costs and error rates, but also through real-time data analysis to help companies quickly find and solve production bottlenecks to ensure that orders are delivered on time. Meanwhile, the seamless integration of RFID technology with ERP, MES and other systems further promotes the intelligent upgrading of enterprises and lays a solid foundation for the digital transformation of the manufacturing industry. In the future, with the continuous optimization of the technology, the system will play a greater value in a wider range of industrial scenarios, helping enterprises achieve the goal of efficient, transparent and sustainable production and operation.