RFID intelligent management solution for material tracking in home appliance manufacturing production lines

Demands of the home appliance industry

The home appliance industry has a fast production pace and many suppliers, which leads to frequent congestion and waiting of vehicles entering the factory. The production line may be shut down due to the lack of logistics of key parts. The traditional production logistics model of the home appliance manufacturing industry mainly relies on manual storage, picking, distribution, verification and issuance of parts, facing problems such as large human resource demand, time-consuming and labor-intensive, low logistics efficiency, difficulty in finding materials and inaccurate inventory information. Competition in the home appliance industry is becoming increasingly fierce, and high requirements are put forward for multiple varieties, multiple batches, short delivery time, low cost, flexible manufacturing, rapid response, energy conservation and emission reduction. Therefore, it is urgent to realize transparent, controllable and intelligent and efficient management of production lines.

Intelligent logistics solutions

We provide a complete set of intelligent logistics solutions for the home appliance production industry, covering manufacturing, distribution, logistics and Asset MANAGEMENT, aiming to eliminate intermediate links, realize transparency and controllability of data information, improve efficiency and reduce the use of human resources. At present, it has achieved huge economic benefits in many leading home appliance companies.

Application link

1. RFID intelligent production line assembly

Customer needs: solve the problems of mixed-flow production, line equipment information islands and quality control improvement.

Solution: Use RFID collection technology to realize unmanned, automatic and real-time identification of single-item products on the production line, and use the real-time collected product information to complete the mixed-flow production material error prevention, real-time push of process guidance, automatic diversion of defective products, automatic generation of quality reports, product traceability management, mixed-flow line change alarm, and automation equipment docking.

Value benefits: New employees' skilled operation time is reduced by 60%, ensuring the accuracy of the assembly process; achieving error-free material assembly; automatic docking of automated processing/testing equipment, automatic configuration and call of programs/parameters; automatic docking and recording of quality data, accurate traceability; automatic diversion of abnormal products, offline repair; visualization of production progress and real-time monitoring.

2. RFID Tool management system

Customer needs: solve the problem of being unable to track tool life in oily, metal and high-temperature environments in the processing workshop, and avoid production stoppage losses caused by short-term or failure of tools.

Solution: Install RFID tags on the tool handle, use tool combination operation, establish an association between the tool handle and the tool in the tool management system, realize the use of RFID to manage tool information, install RFID Readers in the CNC machining center, transform the machine tool PLC, NC and HMI, realize automatic transmission of tool parameters, tool installation verification and tool life control, and cooperate with production line robots and transmission mechanisms to realize automation and unmanned production processes.

Value benefits: No manual intervention in the data transmission process, greatly reducing the error rate; real-time monitoring and updating of tool life information, effectively extending tool life; automatic identification of tool information, more detailed data transparent management; unmanned intervention in product mixed production, distribution and manufacturing processes; the quality defect rate caused by tool machining decreased by 50%, the machine tool utilization rate increased by 8%, and the tool life increased by 20%.

3. Logistics vehicle guidance and unloading

Customer needs: Solve problems such as fast production rhythm, large number of suppliers, and congestion of vehicles entering the factory, and avoid line stoppage caused by the failure of key parts logistics to enter the factory in time.

Solution: RFID electronic tags are distributed to suppliers' vehicles to associate vehicle delivery information (material types, quantities, unloading locations, etc.) as the basis for suppliers' vehicles to enter the factory for unloading and unloading location allocation. Intelligent reservation terminals are configured outside the factory area, so that suppliers can quickly complete unloading location reservations. At the same time, a web version of the online reservation function is provided. Suppliers can access the web page through the external network to make online reservations to avoid early or delayed delivery. LED screens and status display lights are installed on the unloading location to achieve real-time unloading guidance, unloading location idle and busy status display, and unloading timeout reminders. The business management system is customized according to the needs of the enterprise, and seamlessly connected with ERP, MES, WMS and other systems.

Value benefits: Automatic release of supplier delivery vehicles, automatic allocation and guidance of unloading locations, real-time monitoring of unloading location status, unloading timeout reminders, etc. are realized, reducing the vehicle congestion rate at the factory gate by 70%, reducing the abnormal working hours caused by material shortages due to untimely delivery by suppliers by 80%, reducing the workload of security personnel at the factory gate by 5%, saving 50% of resource allocation work (such as forklifts), and reducing warehouse inventory by 15%.

4. Transparency of production line data information

Customer needs: In the face of increasingly fierce competition in the home appliance industry, with high requirements such as multiple varieties, multiple batches, short delivery time, low cost, flexible manufacturing, rapid response, energy conservation and emission reduction, it is necessary to make the production line transparent, controllable and efficient.

Solution: Adopt RFID collection technology to realize unmanned, automatic and real-time identification of single-level products on the production line, and use the real-time collected product information to realize mixed-flow production material error prevention, real-time push of process guidance, automatic diversion of defective products, automatic generation of quality reports, product traceability management, mixed-flow line change alarm, and automation equipment docking.

Value benefits: Reduce the time for new employees to become proficient in operation by 60%, ensure the accuracy of the assembly process; realize error-free material assembly; dock with automated processing/testing equipment to realize automatic configuration and call of programs/parameters; realize automatic docking and recording of quality data and accurate traceability; realize automatic diversion and offline repair of abnormal products; realize visualization and real-time monitoring of production progress.

Typical Cases

Project Background

A well-known enterprise currently uses telephone, email and post-event fines to urge and communicate. There is a lack of early warning mechanism to warn suppliers to deliver goods as soon as possible. The security guards at the gate check and release the vehicles, which easily leads to vehicle congestion at the factory gate and disorderly occupation of unloading resources, which in turn causes an imbalance in unloading scheduling. In the case of emergency delivery, it is necessary to notify the supplier by phone, notify the security guards at the gate to release the vehicles, and manually allocate the unloading position. However, this communication link is cumbersome, the efficiency of avoiding accidents is low, and it is easy to cause production suspension.

Solution

1. Issue RFID electronic tags to supplier vehicles to associate vehicle delivery information (material type, quantity, unloading position, etc.) as the basis for supplier vehicles to enter the factory for unloading and unloading position allocation.

2. Configure smart appointment terminals outside the factory so that suppliers can quickly complete unloading position appointments.

3. At the same time, configure the web version of the online appointment function. Suppliers can access the web page through the external network to make online appointments to avoid early or delayed delivery.

4. Install screens and status display lights on the unloading position to achieve real-time unloading guidance, busy and idle status display of the unloading position, and unloading timeout reminder.

5. Customize the business management system according to the needs of the enterprise and seamlessly connect with ERP, MES, WMS and other systems.

Value Benefit

Realize the functions of automatic release of delivery vehicles of suppliers of home appliance factories, automatic allocation and guidance of unloading positions, real-time monitoring of unloading position status, unloading timeout reminder, etc., reduce the vehicle congestion rate at the factory gate by 70%, reduce the abnormal working hours caused by material shortage due to untimely delivery of suppliers by 80%, reduce the workload of security personnel at the factory gate by 5%, save 50% of resource allocation work (such as forklifts), and reduce warehouse inventory by 15%.