Yueda clothing workshop digital management-clothing RFID on-site management

Analyze common confusion problems in factories and workshops:

- General workers in the workshop often have the habit of storing work tickets. This habit not only increases overtime costs, but also affects the factory's inability to accurately control workers' output.

- The main reasons for low production efficiency are the lack of strict quantification in management, lack of planning in production, low equipment utilization, and uncooperative personnel arrangements.

- Supervision is out of control. When production lags, early warning notices are not issued in a short time. The performance of employees in the production line is uneven and there is a lack of data measurement, which seriously affects the production progress.

- Lack of data for operational analysis. Currently, many factories have used various types of computerized technology networks to control production operations, and these computer program modules support a variety of proprietary settings. This situation not only increases a lot of maintenance costs, but also makes it difficult to collect data for enterprise planning (real-time statistical data in the production process).

Therefore, a comprehensive enterprise information management planning system, RFID production management plan, and ERP solution are the silver bullets for enterprises.

Introduction to using RFID technology in workshop management

The flying operation of the traditional production line, compared with the use of RFID record cards in the WIP process flow: replacing the paper-printed work tickets (flying tickets) of the production line.

It is really difficult for general management to use "work ticket flyers" as a Tool to understand and track production progress. Not only will workers keep their tickets until they are handed over before the pay period (or they will make false wage reports for overtime work), it will aggravate the calculation of wages. In addition to processing and costs, the actual progress of production can also be confused. The RFID system uses preset production component data to be Stored in the RFID system, and the RFID record card is used in the WIP process flow for production process management. When the RFID production card passes through the reader in front of each vehicle or production machine, the start and end of each process can be transmitted to the main server database in real time. The program will automatically calculate and count the production progress and piece wages, realizing "real-time production" Comprehensive tracking and control of "management process", and provides a large amount of analyzable data for production department balance, worker output value, equipment utilization rate, etc.

Through computers, real-time production processes are transmitted to managers at all levels, greatly improving transparency.

How to implement the recording, transmission and management of real-time information in factory production will be discussed in detail at the implementation plan level.

RFID production management solution

RFID production management solution, application production categories include woven, knitted, underwear, woolen, swimwear, jackets, handbags, shoes, etc. What is most praised by customers is that using this system will not change the original operating mode. Today, the production model of most garment factories in China and Hong Kong is based on Bundle Production Mode or Unit Production Mode. The biggest disadvantage of this assembly line production line model is that there is often a backlog of semi-finished products/work in progress (WIP). If the processes are complicated and the production process is lengthy, it further weakens the manufacturer's ability to predict, control and adapt to the production cycle. The traditional production management model has become increasingly difficult to cope with the market requirements that require rapid response and extremely short delivery times. The RFID production management solution provided for the clothing industry is definitely an IT solution to this problem. To put it simply, the RFID production management solution is to add RFID technology to the integration process of different cutting parts, and to systematically track the progress of each processing and production in each production line. Different from the general production line management method, the RFID production management solution does not hinder the tracking of "real-time" production data due to the complexity of different production areas and styles.

Real-time is one of the advantages of this system - the RFID production management solution provides "real-time data" on the production line. Good management emphasizes balanced production, encourages overall operations, and does not purely pursue individual output. The handover of semi-finished products between processes is very close, because any blockage will directly affect the operation of other processes in production. Therefore, the overall production arrangement of workers and machinery capacity is based on the principle of smooth production flow. In addition, the management itself needs to strictly limit the inventory of semi-finished products. Based on the short-spaced design of the production system and the principle of synchronous production, the storage volume of semi-finished products will not be large at all. These restrictions and rules need to be digitized, standardized, and Computerization.

Jiangsu took the lead in successfully adopting RFID production management solutions. One of the factories is a joint venture garment factory (Yueda Textile Group) located in Yancheng, Jiangsu. When asked about the secret of using RFID production management solutions, the person in charge of the factory said that balance Running water is very important. To achieve a balanced flow operation, you must first have a proper production plan and manpower arrangement. In conjunction with the system, the factory's production line Engineering team will conduct process analysis and time research on the ordering styles before production, and determine a production plan, including process time, daily expected production volume, and mechanical equipment layout drawings, etc., which are input into the system. The data is also the production indicator of the cutting bed department, and the backlog of cutting pieces has been reduced through production methods. The management also emphasized that the RFID production management solution can digitize and computerize the production process, so that past problems can be "resolved". Only on the system monitoring screen, managers can calmly use visual management to discover and solve production problems in a short time, greatly reducing the possibility of backlog of problems. If necessary, deployment revisions can be made at any time during production to reduce production line imbalance problems, overall productivity can be improved and costs can be relatively reduced. Generally speaking, the RFID production management solution solves the problems of the traditional production model such as backlog of semi-finished products, difficult quality control, and long production cycle. In today's garment market with thin profits, diversified customer requirements and fierce competition, these common problems are often fatal and should serve as a reference for the garment industry.

RFID production management solution: tracking of people/objects/events, and simultaneous real-time data collection

From the perspective of the entire integrated supply chain (Integrated Supply Chain), the RFID system greatly improves the transparency of each link of the supply chain (different supply chain projects in different regions), and items (including processes) can be tracked in real time anywhere in the supply chain. In terms of the depth and breadth of supply chain integration, integration can be divided into four levels: more accurate information integration, more effective synchronization planning, more effective collaborative workflow and comprehensive supply chain integration. RFID brings revolutionary changes at every level, truly realizing real-time supply chain integration.

The optimized and integrated supply chain environment of RFID technology provides supply chain participants with a new business operation model, allowing enterprises to pursue their goals more effectively.

Real-time information. RFID does not require humans to identify tags. The card reader directly reads the relevant data in the smart card (employee card, process card) from the radio frequency tag. Some card readers can read the data of one or two hundred tags in a very short time, which is a thousand times faster than traditional scanning methods, saving a lot of labor resources (only relying on manual processing). Take production line management as an example. In a supply chain environment with a well-integrated RFID WIP and ERP system, due to the high degree of information sharing, process progress information is placed in the information flow of the entire system and can be queried in real time by all participants and managers. , the stored data can be used for salary calculation purposes, further reducing manpower and errors.

Secondly, the RFID system can effectively promote the supporting strengthening of the supply chain (including ERP system). In a highly coordinated and integrated environment, information flow can cooperate with logistics and capital flows to achieve more flexible business processing, but it is crucial to effectively closely link information flow with related businesses. RFID technology is implemented through ERP systems across departments (and across different collaboration partners). Upstream suppliers and manufacturers and downstream distribution and retailers can track and obtain first-hand information on production progress, thereby reducing inventory. To reduce the occupation of mobile data, materials and products can be stored more accurately and efficiently.

Furthermore, real-time supply chain management is truly achieved. Comprehensive global supply chain integration is like a large virtual enterprise organization. Each member of the organization shares information, synchronizes plans, and uses coordinated business processes to jointly respond to the complex and ever-changing market and provide end customers with efficient, fast, and efficient services. Flexible business to gain advantage from. Through the information system platform integrated with the RFID production management solution, the production lines and processes can be clearly and accurately displayed under any circumstances. Each supply chain participant can also gain insight into the status of the entire supply chain, making the entire supply chain's response speed and Accuracy is greatly improved.

Research and develop, bring forth new ideas, and track all aspects of the clothing supply chain

In order to focus on and adapt to the complexity and particularity of the clothing industry supply chain, the RFID system is not only tracked in the cutting bed, patch room, workshop, ironing department, packaging, etc., the development and research department also develops the washing process in-house. The high-temperature-resistant RFID tag, with its unique opening and thick design, can prevent the tag from falling off and not damaging the clothing material when the washing machine is running, so it is the selling point of the new tag.

Application examples, efficiency index can be seen immediately

As a large-scale garment manufacturer in the Yangtze River Delta, Yueda Textile Group has more than a thousand workers and an annual output of hundreds of millions of pieces, which are exported to major clothing retailers in Europe, the United States and Australia, such as Wal-Mart.

In a garment factory, managing workers and supervising production progress is not an easy task. As far as wage management is concerned, in order to encourage workers to work more and gain more, garment companies generally adopt a piece-based pay method. However, relevant labor laws and social responsibility regulations required by customers also include provisions on minimum wages and overtime wages. Therefore, workers Wage calculation requires consideration and coordination from many aspects.

Before adopting RFID technology, Nanwei Yueda, like other garment factories, calculated wages by cutting work tickets. After workers complete a certain process of a bundle of semi-finished products, they cut out the corresponding work tickets as proof of workload statistics, and then a dedicated person collects them on time to calculate wages.

However, this method cannot accurately grasp the working status and efficiency of each worker. More importantly, it is impossible to quickly and accurately grasp the production progress, and it is time-consuming and labor-intensive. Some workers even keep their regular shift work tickets and put them away in order to get more wages. It is not handed over until the overtime day, which virtually increases labor costs.

With the advent of the era of global integration in the international apparel market and increasingly fierce competition, the market demand for small batches, multiple varieties, and short delivery times has become increasingly prominent. It is obvious that low-efficiency, high-cost, and labor-intensive garment factories cannot meet the demand. .

The RFID production management solution uses employee cards and ID Cards to reflect workers' working status and production line production status to the computer system in real time and accurately, making it easier for managers to grasp production progress in a timely manner. Through digitized information, we can accurately calculate production capacity and production cycle, discover production bottlenecks in a timely manner, and help managers optimize the production management process and improve production capacity.

In addition, the program automatically collects production data, replaces traditional work tickets, automatically calculates wages, effectively supervises workers, enhances workers' sense of responsibility, and makes management more standardized.

Senior administrators of Nanwei Yueda said that after applying the RFID management solution, employee overtime expenses were reduced by 15%, time spent on order follow-up and administrative management was saved by 20%, and overall productivity was directly improved, with the production cycle shortened by 18%. , various operational performance indicators have also improved by 15~25%.