I. Project background
In traditional manufacturing enterprises, daily management is more focused on product management, quality management, warehouse management, mobile asset management, on-site personnel management, fleet management and so on. The collection of production line information is usually done by manual acquisition and manual input. The accuracy of such manual acquisition and manual input is far from sufficient, and there is a large error rate. Manual input can only be carried out at regular intervals, resulting in the production plan being submitted on a weekly basis and a monthly schedule, which cannot be accurate to the day. The production data in the system cannot be updated in real time, and the lag is serious, which is not conducive to the smooth progress of the production flow and restricts the further improvement of production capacity. At the same time, most of the functional departments of manufacturing enterprises use the primary recording method of paper and pen, which makes most functional departments of manufacturing enterprises face a large number of data errors and reduce the overall productivity of the enterprise.
Manufacturing companies are aware of these problems and are trying to solve them with emerging technologies. At present, some production enterprises use barcode recognition to improve the accuracy of data entry, but there are still technical bottlenecks in barcode recognition:
1. The efficiency of workers is different, which is likely to cause uneven division of labor in the group;
2. Production anomalies and production line bottlenecks cannot be discovered in real time;
3. Labor efficiency is low, and the actual working time utilization rate is not high;
4. Bar code labels are difficult to identify once the printing label is unclear and there are problems such as folding marks.
5. It is impossible to track in real time. It is difficult for management to make work arrangements according to the working status. If there is a problem in a certain process in the work process, it must wait until the next day if it is to be excluded;
6. Bar code data collection needs to specially arrange the personnel team to operate, and the labor cost is large;
Therefore, the production line management system represented by bar code recognition has become more and more unable to meet the requirements of enterprises for efficient and lean production management. It is of great significance for enterprises to build a more advanced technology production line management system while deepening modern management concepts.
Second, the project definition
RFID radio frequency identification technology is another emerging high-tech technology that causes changes in the field of automatic identification after bar code. It utilizes the characteristics of wireless electromagnetic wave penetration, long-distance transmission and high-speed data exchange to achieve identification through specific protocols. The technology for automatic identification of item information. In the manufacturing industry, UHF UHF RFID technology has the inherent advantages over the currently widely used bar code technology: wireless long-distance reading and writing, transparent reading and writing, and high-speed movement. Read and write, store more data, use in harsh environments, and more. Therefore, RFID technology is not just a simple replacement of bar code technology, its application in manufacturing industry will change the way of production and operation of enterprises.
The production line management system based on UHF UHF RFID technology is based on computer network, with RFID as the core, the construction meets the requirements of enterprise production management, and aims to solve the existing problems of the enterprise, from the production line semi-finished products off-line, warehouse transfer and The whole process of temporary storage and re-launch production, such as automatic real-time data collection, comprehensive management system for tracking and managing the batch number of goods.
As a data carrier, electronic tags can play the role of identification, item tracking and information collection. The RFID system consisting of electronic tags, readers, antennas and application software is directly connected to the corresponding management information system. Every item can be accurately tracked. This comprehensive information management system can bring many benefits to customers, including real-time data collection and tracking management. Therefore, RFID technology is applied to the tracking and management of goods conversion between production lines. It can effectively prevent errors, realize the intelligent management of production line logistics, and greatly improve the production line management level of enterprises.
Third, the system design
RFID-based production line management system, applying advanced RFID radio frequency identification technology in production lines, dumping and temporary storage warehouses, using reusable radio frequency electronic tags, each tag has a unique ID number, and a readable and writable data area Write product information into RFID electronic tags, install readers at the production line offline station and warehouse entrances and exits, automatically write and collect product information of each location through reading and writing tag information, and share data information with other IT systems. The information is displayed on the display at the same time, prompting the operator of the production line, so as to carry out the whole process tracking management of the semi-finished products from the offline to the warehouse, temporary storage, and on-line production, so as to ensure the correspondence of the batch number of the goods between the production lines. Each production line can complete production tasks without error, and record important information in the production process, which can provide basic data services for future quality information traceability.
3.1 Construction objectives
Manufacturing line companies introduce RFID, combine RFID with existing IT systems, establish a real-time management system for production lines, optimize and more rational use of resources, increase productivity, improve asset utilization, and provide higher-level quality control and various online measurements. Create greater benefits for the company.
RFID provides a constantly updated real-time data stream. Complementing the manufacturing execution system, RFID provides information to ensure the correct use of labor, machines, tools and components for paperless production and reduced downtime. Furthermore, when materials, components and assemblies pass through the production line, they can be controlled, modified or even reorganized in real time to ensure reliability and high quality. All data is collected wirelessly by the client computer wirelessly.
With real-time data flow as the foundation, management systems such as ERP can mine these large amounts of data, conduct real-time and effective supervision of production schedules and processes, identify production bottlenecks, solve production problems, and deploy higher-level quality control and Various online measurements.
RFID provides the most accurate process calculations required for the process. ERP software can accurately calculate each process and working time of each worker through RFID, and calculate the actual production capacity of each production line. Enterprise management personnel can use these data to make a more accurate analysis of the business capabilities of the enterprise.
Complete data mining and analysis, enterprise management personnel master the production capacity of the workshop, solve production bottlenecks in real time, monitor production progress in real time, improve production process through quality monitoring, and RFID provides the basis for enterprises to achieve balanced production lines, and enterprise ERP, SCM, MCS, etc. The combination of mainstream management systems allows every employee in the company to achieve maximum energy efficiency.
3.2 system network diagram
The system mainly realizes intelligent management of the entire production line from card issuance to station management and warehouse management.
3.3 system flow
3.3.1 Card Issuance Management
According to the production order, the production plan is arranged, including production order import, order statistics and status information transfer, production task decomposition, automatic task assignment, etc., according to the production plan, the electronic label is produced and the electronic label is bound to the goods to be managed. And through the ERP sharing interface to obtain product-related information, the information is written into the electronic label, such as batch, box number, etc., the product file is established in the production management system, and the cargo production line conversion process is fully tracked.
3.3.2 Work station management
In each workstation RFID reader and antenna, when the RFID tagged goods enter the RFID working point, the read (write) device reads the data information stored in the electronic tag on the product; the read (write) device reads The electronic data information is directly transmitted to the logistics control management information system. The management system then lists the package number and batch information of the goods according to the product production information, and displays them on the display screen to prompt the production workers to perform correct operations.
3.3.3 Warehouse Management
After the goods are processed on the production line, they need to be sent from the production line to the transfer warehouse. The RFID channel-type reading device can be installed in the dump warehouse to realize the automatic collection and real-time background data update of the goods transferred to the warehouse. The goods are discharged from the warehouse, and the automatic and batch delivery are realized in the same way, realizing the real-time and efficient management of the goods.
Fourth, system revenue
The completion of the RFID-based production line management system can bring the following benefits to the enterprise:
1. Production data can be collected accurately and in real time;
Real-time feedback on production data is the basis for ensuring smooth production operations. The system collects real-time production data in the production workshop. The RFID device automatically collects in real time. The impinj RFID reader reads the specific information contained in the RFID RFID tag into the system in real time, and the server updates the data every 5 seconds. . Through this mode of operation, the system can provide real-time production data for acquisition and data analysis.
2. Productivity is improved on the basis of the original
Productivity is a hot spot of production management and a management difficulty. If productivity is increased, it means that the output of the company will increase and profits will increase. The real-time production data of the production workshop is fed back to the system. Through system monitoring, the reason for hindering the smooth flow of the production line can be found in real time, and the production bottleneck is found in time. The system monitors the production status of each workshop, each group and each station in real time through real-time data collection, so that any abnormal state of production can be found and the bottleneck that hinders production flow is solved in time. The smooth flow of the assembly line has been ensured as a whole, and productivity has been improved.
3. Order progress in real time to ensure timely delivery
If the order cannot be delivered in time, it means that the company can not only make a profit but also cause losses, but also affect the credibility of the company. It will have a great impact on the future development of the company. In particular, export companies are more important for the timely delivery of orders. The system starts with the customer's order and records the real-time progress of the entire production process from the start of production to the end of production. Track the progress of orders on the production line in real time, so as to accurately grasp the production progress of each order and achieve the purpose of timely delivery.