Design and application solution of RFID intelligent production line management system in a factory

Project Background

As a modern manufacturing enterprise, a factory in Dongguan faces challenges such as low production line efficiency and uncontrollable production process. In order to improve the visual management level of the production line, they decided to introduce RFID technology to achieve real-time monitoring and optimized management of the production process.

The traditional production line management method has the following difficulties

Lack of real-time monitoring: The factory cannot understand the production situation on the production line in real time, and cannot find problems in time and take corresponding measures.

Uncontrollable production process: The factory cannot accurately grasp the location and status information of the work-in-progress, resulting in uncontrollable production process, affecting production efficiency and product quality.

Human errors and delays: Due to the inaccuracy and delays of human operations, problems such as assembly errors of spare parts and delays in production progress often occur on the production line.

Traditional production management system is difficult to monitor and inefficient

Solution

To solve the above problems, the factory introduced an RFID production line management system to improve production efficiency and product quality. The solution is based on RFID technology and combines advanced technologies such as the Internet of Things (IoT) and data analysis. It can monitor the production situation on the production line in real time, accurately grasp the location and status of work-in-progress, and avoid human errors and delays.

System composition

RFID data collection system

This solution realizes real-time dynamic tracking of the position and status information of work-in-progress by installing RFID Readers on the raw products and assembly lines, and adding RFID tags to each raw product. When the raw product moves to the Library-borrowing-machine-touch-query-intelligent-terminal-all-in-one-machine.html target='_blank'>workstation on the assembly line, the worker can identify and remove the recycled product through the RFID tag for spare parts assembly, and then put it back to the assembly line after completion until all processes are completed.

Station controller

The station controller is a key component used in conjunction with the RFID data collection system. It realizes the control of the raw product at the workstation through communication with the RFID reader. The station controller can automatically adjust the operating status of the station equipment according to the identification results of the RFID tag to ensure that the raw product can be smoothly assembled with spare parts.

Kanban and path selection actuator

In order to improve the flexibility and efficiency of the production line, the solution introduces kanban and path selection actuator. Kanban can display the current status and required operations of the raw product to help workers quickly understand the task requirements. The path selection actuator automatically selects the best path and workstation according to the information of the RFID tag, guides the raw product to the correct location, and reduces transportation time and human errors.

Solution Features and Advantages

Real-time data collection and status monitoring: Through RFID technology, real-time data collection and monitoring of equipment status and production process are realized, helping enterprise management to quickly discover production line problems and make timely adjustments and optimizations.

Multi-faceted data collection and integration: Using RFID tags, readers, wireless sensor networks and other technologies, real-time collection of multi-source heterogeneous data such as materials, work-in-progress, and execution equipment is realized, and it is efficiently integrated with the company's ERP, MES and other systems to achieve full life cycle management of products.

Public resource positioning and scheduling: Through RFID technology combined with other sensors and equipment, spatial positioning, operation trajectory tracking, idle and busy status judgment and task scheduling of public resources (such as Engineering forklifts, workshop flatbed trucks, etc.) are realized, improving the operating efficiency and responsiveness of the manufacturing system.

Production plan execution process monitoring and visual management: Through workstation readers, electronic pallets, RFID tag pendants and other products, a visual monitoring platform for the production process is realized, the production process of the product is tracked throughout, and key information such as automatic reporting, completion quantity, current process, execution equipment and operators are recorded, providing data support for planning and scheduling, line-side materials, on-site logistics and quality traceability.

Improve the company's reputation and quality system construction: By establishing a product traceability system, recording the production process and quality information of the product, improving the company's product reputation, establishing a complete quality system, and providing a basis for the company's value engineering.

Solution benefits

By introducing the RFID production line intelligent management design application solution, a factory in Dongguan has realized the visual management of the production line, improved production efficiency and product quality. The characteristics of this solution include real-time data collection and status monitoring, multi-directional data collection and integration, public resource positioning and scheduling, production plan execution process monitoring and visual management, and improving the company's reputation and quality system construction. These characteristics and advantages provide strong support for the sustainable development of the enterprise.