Application of RFID systems and tags on production lines

It's easier said than done, and radio frequency identification (RFID) systems and tags are still quite expensive. Considering that almost all goods are labeled, and the labels are difficult to reuse, the cost can be imagined. Therefore, when Wal-Mart notified its 100 largest suppliers in June 2003 that all RFID tags must be used, and that the equipment was to be fully in place at the delivery center before January 2005, many suppliers were busy trying to improve their return on investment. (ROI) and reduce costs.

One of the 100 largest suppliers is Wells' Dairy, which supplies Wal-Mart with Blue Bunny ice cream and a variety of small items. According to Wells' report, it is the largest family-owned dairy company in the United States and operates the world's largest ice cream manufacturing facility, located in LeMars, Iowa, for up to 160 hours a week.

Many vendors label their labels before shipping in order to comply with the new RFID regulations, but Wells's different approaches. It used RFID systems early in the manufacturing process, saving money and achieving other advantages. Wells' process control manager Brad Galles began a pilot project with dairy company automation supplier Rockwell AutomaTIon in mid-2004. The internally developed solution uses the Allen-Bradley 1756 EWEB module for ControlLogix to process data from Alien Technology's RFID reader and the 915-Mhz, 96-bit Squiggly tag.

The antenna reader is written on the RFID tag, which is attached to the outer package of the two-barrel product and can be attached to 30 outer boxes per minute. When the quick freezing is performed, the label on the outer box is read again, and the speed is up to four times that of the previous one, and finally the product is shipped. The RFID system passes the information back to the Wells' control system to enable information sharing in the company's corporate network. Galles explained that if the system is shipped with the usual label and then shipped, Wells' must introduce manual repackaging, which will increase labor costs.

Galles pointed out: "We have been using RFID technology since the beginning to promote process change and improve performance. Once data is collected, we can use it to improve catalog tracking, automate most quality control and catalog work, and simplify data collection. Work. "Wells' report also shows that its RFID system frees employees from heavy work, reduces shipping errors, and minimizes manual repair work.

The dairy company and Rockwell achieved efficiency gains through RFID systems, leveraging the data processing capabilities of the tags. For example, each RFID product of a dairy company is connected to a database with production parameters for the ice cream in the package, including production time, batch identification information, and product lines. This allows Wells' company operators to accurately understand when each label is pasted, and which batch of shipments belong to the batch.

In summary, the advanced features of RFID tag identification data help to strengthen the physical state and environmental data of the user database, ensure process changes or test validation, and support related decisions and implementations to further improve product quality.

Galles pointed out: "The role of RFID is that it can enhance the visibility of factory production, because we can use RFID to collect information, and the way information is collected is matched with existing equipment, which creates more value for us. To achieve the highest return on investment, we should continue to use the ControlLogix platform used in the existing process to design the RFID system."

RFID basics

RFID tags do not need to monitor the production line and can process more data. Although barcodes are ubiquitous and relatively inexpensive, RFID tags are more robust and should replace barcodes. In addition, RFID is less expensive than traditional radio transmitters and other wireless technologies.

However, in terms of current applications, RFID is primarily used for identification, material handling, and other types of documentation. This meets the requirements of Wal-Mart and the US Department of Defense (DoD) for installing RFID systems. People have given great expectations to the development of this technology, but there are reports that it still faces obstacles in its implementation and there are doubts about the return on investment. Therefore, the implementation of RFID should not be rushed.

In view of this, in general, how to develop applications depends on the user to be the master. Users should be clear about their needs, understand the functions and costs of RFID, and then decide whether RFID can help improve work efficiency, promote decision-making, and enhance quality. Control and promote production. If not, users will still choose technologies such as barcodes, radio transmitters or wired networks.

Bill Arnold of Omron Electronics LLC states: "If the data acquisition system sees the barcode with its 'eyes', then it can also hear the RFID tag information through the 'ear' of the system, but also through the system's 'language' Talking to it. RFID technology is clearly a better way to achieve control and visibility into the supply chain. Barcodes are only 14 to 16 digits, and each RFID tag has 96 to 256 digits as a A unique technology that can be used to clarify the various parameters of the product, including production shifts, machine tools used, and operators."

The RFID tag can be read-only, write-once multiple read (WORM), read-write, passively read by an antenna/reader, or actively transmitting a signal (usually battery assisted).

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