CN101639912A - Production Monitoring System Based on Radio Frequency Identification - Google Patents

Abstract

A production monitoring system based on radio frequency identification, the system includes a plurality of radio frequency identification tags, which are attached to the manufactured products, product packaging, equipment or operators, or attached to the production tracking station at the production point of the items, and the data of the radio frequency identification tags can be read and written at a production tracking station; a plurality of production tracking stations, which are used to read data from the tags or write data into the tags; a data collection and filtering unit, which is respectively connected to the plurality of production tracking stations and a database; a data control unit, which is respectively connected to the data collection and filtering unit, the data analysis module and the database; a data analysis module, which is respectively connected to the data control unit, the host system and the database; a host system, which is respectively connected to the data analysis module and the database. The present invention can automatically track the production process in real time, and display the production and tracking data in images, so as to effectively manage human resources and resources, improve and optimize the production process, and ensure the smooth and reliable production process.

Description

Production Monitoring System Based on Radio Frequency Identification

【Technical field】

The invention relates to a real-time monitoring system of product production and manufacturing process, in particular to a production monitoring system based on radio frequency identification.

【Background technique】

In the existing paper-based production monitoring method, the progress and production date can be written on the paper, and the paper is pasted on the work-in-progress, the truck or the container for transporting the goods. No systematic research has been done to track the production process or to obtain accurate data for data analysis. In addition, there is no research on operational control, such as ensuring correct sequence, suitable personnel, trouble-free process, etc. As the data is handwritten, errors may occur during this process.

European patent application WO 00/45324 discloses a method for production and operation management using read-write radio frequency identification tags, which is a method for production and operation management by attaching read-write radio frequency identification tags to items in process. Information related to each production process can be read and written. Thus, data can be written to the tag and provide information for the next process.

US patent application US 2003/0023337 A1 discloses a manufacturing method with a system that automatically tracks the consistency of a manufacturing process involving continuous production. Following the successful completion of a manufacturing process, relevant conformance data is written to the tag. Only when the previous process is successful, the second manufacturing process will start, and the data of the previous process can be obtained by reading the conformity data in the tag.

The techniques described above are relevant to the present invention, but they do not track and monitor production data with graphical displays, nor do they focus on operators, for example, do not check that the production process is being operated by correctly assigned personnel. Moreover, we propose a unique design of a production tracking station for obtaining production data.

【Content of invention】

The present invention aims to overcome the problems in the prior art, and provides an automatic real-time tracking of the production process, image display of the production and tracking data, so as to effectively manage manpower and resources, improve and optimize the production process, A production monitoring system based on radio frequency identification to ensure the smooth and reliable production process.

In order to achieve the above object, the present invention provides a production monitoring system based on radio frequency identification, the system includes:

Multiple radio frequency identification tags, which are attached to manufactured products, product packaging, equipment or operators, or attached to the production tracking station at the production point of the item, and the data of the radio frequency identification tag can be read and written at one production tracking station;

Multiple production tracking stations for reading data from or writing data to tags;

A data collection and filtering unit, which is respectively connected to multiple production tracking stations and databases;

A data control unit, which is respectively connected with the data collection and filtering unit, the data analysis module and the database;

A data analysis module, which is respectively connected with the data control unit, the host system and the database;

A host system is respectively connected with the data analysis module and the database.

The radio frequency identification-based production monitoring system (RFID-Based Production Monitoring System) RPSM of the present invention is a production tracking station that directly pastes a radio frequency identification-based label on the manufactured product or product packaging box, or attaches it to the production point of the object. To understand the system of work-in-progress inventory. This is a tool for real-time monitoring or process control. Production monitoring system (RPSM) with radio frequency identification technology of the production platform can provide a graphical display of the production process, so that data such as actual cycle time, actual cycle time, running time, etc. as well as inventory and other production statistics can be understood. RFID tags are attached to objects in process, including but not limited to work in progress, work in progress, trucks, machinery and other equipment. On the other hand, operators like operators carry mandatory radio frequency identification tags (RFID cards) so that the operator tags are linked to the production process to ensure that the process is operated by authorized personnel. How much of an employee's job performance contributes to production can be known, thereby optimizing staffing and improving product quality. During the production process, the tag's data can be read and written by a production tracking station. The data obtained can be further analyzed through an integrated monitoring system to identify bottlenecks at different production points to improve efficiency. The tracking data, analysis results and production data in the whole production process can be displayed on the image. The production tracking station will indicate if something went wrong in the process, such as missing programs or wrong instructions. Production Monitoring Systems (RPSM) help manufacturers extract valuable data from RFID more quickly and efficiently. RFID information can be used to obtain justified parts of labor, machinery, tools so that they can be used in every step of the manufacturing process to eliminate paperwork and reduce downtime.

Production Monitoring System (RPMS) can be used in different kinds of manufacturing plants, such as textile printing and dyeing and vehicle manufacturing, etc. Using the production monitoring system, accurate, real-time data can be collected or written from objects in process attached to each production point, tags on trucks carrying items in process and machinery, and staff tags of operators. Initial data includes, but is not limited to, the schedule and procedure of the dyeing process, product information such as name, type and size, identities of machinery and personnel specified, and production data such as materials, sources, and special equipment used for production, which may be Preload into tags. If the server is network connected, production data can optionally be retrieved from the server via a product tracker. On the other hand, operators at each production point, such as operators, carry mandatory RFID tags with employee information related to the date of production. Prior to the start of the production process at each point, staff tag identities are linked via production tracking stations to tags attached to work in process, trucks, or machinery. A warning signal will be issued if the procedure, machinery or staff status is not as specified. If there are no errors, the work starts and the date and time of completion, machine id, etc. can be written to the tag, and if the production tracker is connected to the network, these data can be updated within the server. This ensures that production procedures are correct and run by the right personnel. The progress of the manufacturing process and the real-time data in the entire production chain can be tracked and displayed in images, so that managers can know whether there is any delay in the progress. They can determine whether to change schedules or work overtime. Image display may be provided via a computer, workstation, personal digital assistant, or any other connected image output device. The user can predetermine a threshold value for a production date. In the event of serious problems or errors that exceed predetermined thresholds, the system will warn by signal or visual indication. Users can cooperate with the system by operating keyboard, mouse, touch screen, voice recognition or other suitable input devices and user interfaces.

The RFID tags are loaded with raw data including production data, product data and personnel and equipment data.

Production data includes production schedule, process, material, source and special equipment used for production; product data includes product name, type and size; personnel and equipment data includes the identity of personnel and designated machinery.

Data within the RFID tag can optionally be retrieved and updated from a network-connected host system server via a production tracking station.

The production tracking station is integrated with an interrogator, an extendable antenna and an indicator connected to the interrogator. The interrogator is connected to the tag through an extendable antenna. The data obtained by the production tracking station is sent to the If the data analysis module does not follow the predetermined procedures during the process, the data control unit will send a warning signal, and the indicator of the production tracking station will send a signal to the operator with LED light or buzzer sound.

The data collection and filtering unit, the data control unit and the data analysis module are all software modules.

The data collection and filtering unit is used to filter and collect the data defined by the data control unit; the data control unit provides the drawing between the collected data and the business process, and controls the data filtering standards of the data collection and filtering unit; the data analysis module contains A plurality of data analysis units, each data analysis unit includes a data monitoring and alarm unit, a tracking and tracing unit, a resource management unit, a personnel management unit, and a process and progress control unit.

The tracking system of the present invention is easily adjustable to suit different industries. The integrated monitoring software provides an interface to the host computer via messages such as XML. In production, it is convenient and easy to increase or decrease the process, so it is a flexible multi-functional system. For example, in the printing and dyeing industry, some processes are optional, such as bleaching before dyeing. To modify the production process by appending such programs, the host system will interface with the data control unit of the system to update the rules and criteria for data acquisition and filtering. Thus, the entire monitoring process can be customized.

The system can track the progress of the production process and real-time data along the entire production chain and display computer-based images through radio frequency identification tags and production tracking stations.

This computer-based graphical display of the production process allows managers to monitor process status, inventory consumption status, actual production performance, including accurate measurements of cycle times, batch sizes, and more. The system displays data in different screens, including annual, monthly, weekly summary or process and detailed analysis of each batch in production. It is a user-friendly, accurate data reflection so that managers can monitor the entire production process and make decisions and plans. It is convenient for administrators to issue a warning when the data exceeds the user's predetermined value, such as the tag cannot be read for "n" minutes.

The invention supports both online and offline modes of system operation. Since RFID tags allow data to be written, the requested data includes, but is not limited to, the progress and procedures of the printing and dyeing process; product information such as name, type, size; identities of designated machinery and personnel; production data such as materials, sources and Special equipment used for production, these data can be pre-loaded labels. In addition, actual operating data, such as work start time, work end time, machine identity, etc., can be written into tags at each production inspection point. Therefore, the system can still function at sites without web tools. On the other hand, if there is a network, the system can run online so that data can be loaded to, or retrieved from, the server.

The contribution of the present invention is that it effectively solves the following problems:

1. Misplacement of materials or products

Materials or products can be tracked through RFID-based monitoring systems. If the system finds that the material associated with the label does not correspond to the material assigned to the point of production, the indicator will issue a warning signal.

2. Incorrect production process sequence

At each production point, the manufacturing process begins only when the preceding process or steps have been successfully completed, or are in a predetermined correct sequence, which can be known by reading consistent data from tags. Warnings or alerts are issued to operators if an incorrect sequence of the manufacturing process occurs.

3. The missing production process

Similar to an incorrect sequence, if any process is missed, a warning or alert is issued to the operator.

4. Increase in inventory

Errors due to incorrect sequences or missed processes may require additional material, creating excess material. As a result, inventory levels increased. If the system can monitor inventory consumption and status in real time, managers can immediately reduce buffering inventory levels.

5. Lack of systematic and accurate data

At present, many production plants still use paper and handwriting to record data in the production process. This system of collecting production data is unsystematic and unreliable. The production monitoring system can acquire and analyze data in real time and accurately.

6. Limited data available in production

Complete production-related data cannot be recorded due to paper format limitations. However, RFID tags have memory so that valuable data can be recorded.

7. Various limitations are overcome

Data integrity and process reliability. In addition to capturing real-time data, updating of bi-directional data within RFID tags is important for mutual authentication. This will ensure data integrity and facilitate offline verification of data. With the help of industrial control and automation technologies, certain key process flows can be automated to reduce human errors and achieve higher process reliability.

8. Harmful environment

The environment of some production plants is harmful, such as the printing and dyeing room has high temperature, humidity and is full of different chemical materials. Keeping RFID tags and readers as effective and reliable as they are under normal conditions presents challenges.

The present invention has following salient features:

Accurate and real-time data can be easily obtained by using the production monitoring system (RPMS), and managers can better understand how the production process and material and material flow are carried out. The recording system can:

1. Automatic real-time tracking of the production process

Real-time tracking of production activity, including when tasks are started and completed, by whom and by which machine is available at each point of production, allowing production progress to be monitored and potential problems to be warned in advance. Monitoring inventory consumption and status and collecting actual production conditions, including requirements, cycles, batches, and inventory levels can reduce inventory and manpower waste, while ensuring smooth and reliable production processes. Appropriate decisions can be made and prompt action should any issues arise during production.

Data is automatically captured and further analyzed in the system. The system automatically verifies that the correct part goes into the next step in the production process and that the proper action should be taken by the right person. This helps to automate production monitoring. A measure of actual performance can thus be obtained.

2. User-friendly and complete graphic display of production and tracking data

The system provides managers with a user-friendly and complete graphical display of production and tracking data. Depending on their needs, they can determine yearly, monthly and weekly data reporting for the production process. They can also monitor statistics for each batch produced. Based on sufficient data obtained from the system, managers can make quick and accurate decisions on schedules, inventory operations, etc. Visibility helps accelerate adoption of favored production management.

3. Human and resource management

At each production site, during daily operations, RFID tags carried by operators are linked to tags attached to production components, machines, instruments or equipment. Thus, an operator's process knowledge is tracked, their operations and his or her performance can be tracked automatically and in real time, and staffing can be optimized. In addition, by tracking bottlenecks in the production chain, work assignments outside the schedule can be used to evaluate staff performance.

4. Asset Utilization

Reusable assets such as totes, containers, pallets, and tacks can be used in production to move raw materials, work in progress, and finished products. RFID tags on reusable assets allow a company to track those assets over time. Information can be collected including who occupies these assets, what is their content, and whether any repairs performed have been completed.

5. Process improvement

Accurate and sufficient data for each production point, deadlines for each process and rework effort data are available in a timely manner. Managers can identify and prioritize production process improvements. Production cycle times can be shortened by seeking improvements to processes and process sequences utilizing exact data from each production point.

【Description of drawings】

Fig. 1 is a system structure block diagram of the present invention.

FIG. 2 is a schematic structural diagram of the production tracking station of the present invention, wherein FIG. 2A is a schematic diagram of the antenna in a non-retractable state, and FIG. 2B is a schematic diagram of the antenna in a telescopic state.

Fig. 3 is a schematic diagram of an embodiment of the printing and dyeing process of the system of the present invention in the textile and garment manufacturing industry.

Figure 4 is a schematic diagram of the operation and data flow of each production site of the present invention.

Fig. 5 is a schematic diagram of an example of image display of production tracking in the online tracking mode of the present invention.

Fig. 6 is a schematic diagram of an example of image display of production tracking in the periodic report mode of the present invention.

【Detailed ways】

Referring to Fig. 1, the production monitoring system based on radio frequency identification of the present invention comprises a plurality of radio frequency identification tags 1, a plurality of production tracking stations 2, a comprehensive monitoring software module 3, a database 4 and a host system 5, wherein:

A plurality of radio frequency identification tags 1 are attached to the product in progress, and the data of the tags 1 can be read and written at a production tracking station.

A plurality of production tracking stations 2, the structure of which is shown in 2. As shown in FIG. 2A , the production tracking station 2 includes an interrogator 21 , an antenna 22 , a light emitting diode (LED) 23 and a buzzer 24 , and the interrogator 21 is used for reading and writing data from tags. The antenna 22 is connected to the interrogator 21 for receiving or sending out radio waves. As shown in Figure 2B, the antenna 22 can be extended to form a probe associated with the tag. A Light Emitting Diode (LED) 23 is connected to the interrogator 21 and acts as an indicator to send a light warning signal to the operator if any error occurs or further action is required during the production process. The buzzer 24 is connected with the interrogator 21, and when a problem occurs in the production process, it sends a sound alarm signal to the operator as an indicator. Multiple production tracking stations 2 are used to read data from or write data to tags. The production tracking station is connected to the tracking system through the data collection and filtering unit. If an error occurs during production, indicators at the production tracking station will warn the operator not to start the operation.

The comprehensive monitoring software module 3 includes three parts, among which the data collection and filtering unit 3a is a data pool. It can filter and collect data defined by the data control unit. The data control unit 3b provides a mapping between the collected data and the business flow, and controls the data filtering criteria of 3a. This unit enables some low-level data analysis, such as checking that the process sequence is correct. If not, then it will send information to the production tracking station and data analysis module. The data analysis module 3c contains multiple data analysis units, including a data monitoring and alarm unit, a tracking and tracing unit, a resource management unit, a personnel management unit, and a process and progress control unit. These units perform different kinds of high-level data analysis from the collected data, including analysis of production processes, resources, etc.

Fig. 3 shows an embodiment of the printing and dyeing process of the system in the textile and garment manufacturing industry. The system includes:

Yarn or fabric transportation station A: RFID tags 1A1-1AN are pasted on fabrics 101-n01 and connected with them, and the relationship between fabrics and labels is established and recorded in the system. The schedule, designated personnel, machine identity, list of materials and equipment used for production, and product data such as color, size, batch size, etc. are all pre-loaded into the labels 1A1-1AN. After being combined with tags, items 101 to n01 become 102 to n02 and are transported to the next station.

Fabric printing and dyeing station B: the radio frequency identification tags of the operator (can be more than one), that is, the personnel tag 1B is connected with the tags 1B1 to 1Bn. The production tracking station 2B reads the data collected by the data collection and filtering unit from the tags 1B1 to 1Bn. The collected and filtered data is further analyzed by the data control unit and data analysis module. If there is any error in the process, such as sequence error or program error, the production tracking station 2B will send an alarm signal to the operator through LED or buzzer. If the printing at this station is successful, the actual run data is written to the labels 1B1 to 1Bn, and after this process, the items 102 to n02 become 103 to n03 and are shipped to the next station.

Spinning and drying station C: the radio frequency identification tag of the operator (can be more than one), that is, the personnel tag 1C is connected with the tags 1C1 to 1Cn. The production tracking station 2C reads the data collected by the data collection and filtering unit from the tags 1C1 to 1Cn. The collected and filtered data is further analyzed by the data control unit and data analysis module. If there is any error in the process, such as sequence error or program error, the production tracking station 2C will send an alarm signal to the operator through LED or buzzer. If the drying at this station is successful, the actual run data is written to the tags 1C1 to 1Cn, and after this process, the items 103 to n03 become 104 to n04 and are transported to the next station.

Ironing station D: the radio frequency identification tag of the operator (can be more than one), that is, the personnel tag 1D is connected with the tags 1D1 to 1Dn. The production tracking station 2D reads the data collected by the data collection and filtering unit from the tags 1D1 to 1Dn. The collected and filtered data is further analyzed by the data control unit and data analysis module. If there is any error in the process, such as sequence error or program error, the production tracking station 2D will send an alarm signal to the operator through LED or buzzer. If the ironing at this station is successful, the actual run data is written to the tags 1D1 to 1Dn and after the process the items 104 to n04 become 105 to n05 and are shipped to the next station.

Fabric processing station E: the radio frequency identification tags of the operator (can be more than one), that is, the personnel tag 1E is connected with the tags 1E1 to 1En. The production tracking station 2E reads the data collected by the data collection and filtering unit from the tags 1E1 to 1En. The collected and filtered data is further analyzed by the data control unit and data analysis module. If there is any error in the process, such as sequence error or program error, the production tracking station 2E will send an alarm signal to the operator through LED or buzzer. If the processing process at this station is successful, the actual running data is written to the tags 1E1 to 1En, and after this process, the items 105 to n05 become 106 to n06 and are shipped to the next station.

Quality Assurance Department F: the radio frequency identification tags of the operator (can be more than one), that is, the personnel tag 1F is connected with the tags 1F1 to 1Fn. The production tracking station 2F reads the data collected by the data collection and filtering unit from the tags 1F1 to 1Fn. The collected and filtered data is further analyzed by the data control unit and data analysis module. If there is any error in the process, the production tracking station 2F will send an alarm signal to the operator through LED or buzzer. If any item, say n06, passes the quality evaluation, it is sent to the warehouse. Otherwise, the quality assessor will log the defect and the process will have to be reworked in the system. Items are sent to the appropriate production site for repair.

Figure 4 shows the operation and data flow of each production site. As shown in Fig. 4, the person tag 1 is connected to the tags 1A to 1n on the article (L1). The data transmission (L2) from the tag to the production tracking station includes the information of personnel identity, item identity and other related procedures m. The data transmission (L3) from the production tracking station to the data collection and filtering unit 3A includes personnel identification, item identification and other relevant data collection station information in procedure m. Alarms and other production data can be transmitted (L4). Additional production data can be transferred (L5).

Fig. 5 shows an example of image display of production tracking in the online tracking mode.

As shown in Fig. 5, the image display appears on an output device or user interface, and there is at least one application program window on the output device or user interface, and the application program window may include:

Displays a menu bar 6 of commands that can be used to control the image display.

Window component 7, such as a pull-down menu, is used to select a special batch production within a specified operation period.

Window components 8, such as a list box and a combo box, are used to display a list of processes limited to a particular mass production, and the processes can be selected, edited, deleted and added.

The up and down buttons 9 are used to adjust the sequence of the production process after the process is selected from the list.

A plurality of buttons 10 for adding, editing, and deleting processes in the list.

Progress Tracking Chart 11 for displaying the calculation of the workload out of schedule in each process.

Problem and error chart 12, used to show various problems or errors in each process, such as wrong work order, incorrect title, etc.

Inventory Chart 13, used to show inventory of materials or items in process.

Fig. 6 shows an example of image display for production tracking in periodic report mode.

As shown in Fig. 6, the image display appears on an output device or user interface, and there is at least one application program window on the output device or user interface, and the application program window may include:

Displays a menu bar 14 of commands that can be used to control the image display.

Period selection panel 15, which contains widgets such as drop-down menus to allow the customer to specify the reporting period, such as year, month, week or day.

Detail panel 16, which displays a summary chart for a particular process or for all processes.

Progress Tracking Chart 17, which is used to show the calculation of the workload out of schedule in each process.

Inventory chart 18, which is used to show the inventory of materials or items in process.

Questions panel 19, which graphically displays a particular kind of question or a summary of various questions displayed on the panel.

Problems and errors chart 20, which shows the total number of problems or the number of special problems such as wrong work order, incorrect title for a specific time period, etc. in a graph.

Claims (8)

1, a kind of production monitoring system based on radio-frequency (RF) identification, this system comprises:

A plurality of RFID tag, they are attached on product, product package material, equipment or the operating personnel of manufacturing, or invest the production tracking station of article production, and the data of RFID tag can be a production tracking station read-write;

A plurality of production tracking station is used for writing label from the label reading of data or with data;

Data are collected and filter element, and it links to each other with a plurality of production tracking stations and database respectively;

A data control module, it links to each other with data aggregation and filter element, data analysis module and database respectively;

A data analysis module, it links to each other with DCU data control unit, host computer system and database respectively;

A host computer system, it links to each other with data analysis module and database respectively.

2, the production monitoring system based on radio-frequency (RF) identification as claimed in claim 1 is characterized in that, is loaded with the raw data that comprises production data, product data and personnel and device data in the described RFID tag.

3, the production monitoring system based on radio-frequency (RF) identification as claimed in claim 2 is characterized in that, described production data comprises manufacturing schedule, technology, material, source and produces used specialized equipment; Product data comprise name of product, type and size; Personnel and device data comprise the identity of the machinery of personnel and appointment.

4, the production monitoring system based on radio-frequency (RF) identification as claimed in claim 2 is characterized in that, can select by a production tracking station from the retrieval of the host system server that is connected with network with upgrade data in the RFID tag.

5, production monitoring system based on radio-frequency (RF) identification as claimed in claim 1, it is characterized in that, described production tracking station is integrated with interrogator, the extensible antenna and the indicator that link to each other with interrogator, interrogator links to each other with label by extendable antenna, the data that production tracking station obtains are sent to data analysis module by data aggregation and filter element and DCU data control unit, if occur not following preset program in the process, then DCU data control unit then sends warning signal, production tracking station indicator will be with LED luminous or buzzer call send signal to operating personnel.

6, the production monitoring system based on radio-frequency (RF) identification as claimed in claim 1 is characterized in that described data aggregation and filter element, DCU data control unit and data analysis module are software module.

7, the production monitoring system based on radio-frequency (RF) identification as claimed in claim 6 is characterized in that described data aggregation and filter element are used to filter and collect the data that defined by DCU data control unit; DCU data control unit provides collected data and the drawing between operation flow, and control data is collected and the data filter standard of filter element; Data analysis module contains a plurality of data analysis unit, and each data analysis unit comprises data monitoring and alarm unit, tracking and tracing unit, rm-cell, personal management unit and technology and progress monitoring unit.

8, as arbitrary described production monitoring system in the claim 1 to 7 based on radio-frequency (RF) identification, it is characterized in that this system can follow the tracks of with the computer based image the progress of production run and the real time data on the whole production chain by RFID tag and production tracking station and show.

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