In the manufacturing industry, moulds are the core assets of production, but the traditional management often due to high artificial dependence, data lag, process fragmentation and other issues leading to inefficiency. وتتفاعل (تعريف تردد الراديو) technology through automated data collection, real-time status monitoring and intelligent decision-making support, to significantly improve the efficiency of the mould management, which is specifically embodied in the following five dimensions:
Real-time tracking: goodbye to ‘difficult to find the mould’, shorten the preparation time
Pain point: traditional management relies on manual recording of the mould location, large factories to find the mould time accounts for more than 30% of the production preparation.
RFID solution:
- second positioning: embedded in the mould metal-resistant RFID tags, combined with the workshop fixed read-write and positioning system, real-time display of the mould location (such as ‘No. 2 injection moulding machine is in use’).
- Full-process traceability: Automatically record the flow path of moulds from warehouse to production line, and shorten the time of mould adjustment by 50%-80%.
القضية: An auto parts company reduced the mould search time from 30 minutes to 2 minutes through RFID, and increased annual production capacity by 15%.
Automated data collection: reduce manual intervention, eliminate human error
Pain points: manual recording of the number of times the mould is used, maintenance records are prone to error, resulting in overload or maintenance omissions.
RFID solution:
- Dynamic data writing: RFID tags automatically record key data such as mould up time, moulding cycle, cumulative number of times used, إلخ., with an accuracy rate close to 100%.
- Batch identification: Fixed reader can identify hundreds of tags at the same time, in and out of the warehouse to improve efficiency by 5-10 مرات.
القضية: a home appliance company through RFID to achieve automatic collection of mould data, manual inspection costs down 30%, data error rate to zero.
Preventive Maintenance: Extend the life and reduce the loss of downtime
Pain point: traditional maintenance relies on experience, sudden failure of moulds leads to huge loss of downtime.
RFID solution:
- Lifespan prediction: The system automatically triggers maintenance work orders based on the number of times used, pressure temperature and other data recorded by RFID.
- Health record management: The tag stores maintenance records, replacement parts and other information, forming a ‘digital history’ of the mould.
القضية: A 3C enterprise through RFID predictive maintenance will reduce the failure rate of moulds by 40%, life extension of 20%, annual savings of 1.5 million yuan in maintenance costs.
Process automation: seamless collaboration to enhance overall efficiency
Pain points: Mould allocation, صيانة, scrapping and other aspects of the process rely on manual coordination, process inefficiencies.
RFID solution:
- And MES / ERP linkage: RFID data is automatically synchronised to the management system, triggering work orders, updating inventory status, eliminating information silos.
- Intelligent scheduling: Combined with AGV trolley and RFID positioning, to achieve the automatic allocation of moulds and on the machine.
القضية: a medical device company through the RFID system to shorten the mould replacement time by 65%, the production plan implementation rate increased by 25%.
Active error prevention: Reduce human errors and guarantee production quality
Pain point: Manual operation can easily lead to mould mis-installation and parameter errors, which can cause quality accidents.
RFID solution:
- Model Matching Verification: The injection moulding machine reader automatically checks the mould ID and work order requirements, and locks the equipment if it does not match.
- Anti-tampering of process parameters: The tag stores the range of permitted parameters, and the system monitors and alarms in real time.
القضية: A daily chemical packaging company through the RFID error prevention system to reduce 95% of the mould loading error, product defective rate down by 30%.
The underlying logic of efficiency improvement: data-driven decision-making
RFID not only solves the problem at the execution level, but also feeds the management through data:
- Resource Optimisation: Analyse the data of mould utilisation rate, eliminate the inefficient assets, and reduce the redundant purchasing by 20%.
- Digital Twin: RFID data drives virtual mould models, reducing the number of mould trials by 40% and shortening the R&D cycle.
موجز: RFID is the ‘catalyst’ of the efficiency revolution
Through accurate tracking, automated collection, preventive maintenance, process synergy and active error prevention, RFID will transform mould management from ‘passive fire-fighting’ to ‘active control’, directly improving production efficiency. RFID transforms mould management from ‘passive fire-fighting’ to ‘active control’, which directly improves production efficiency and reduces operating costs. In the era of Industry 4.0, RFID is not only a technical tool, but also a core engine for manufacturing industry to achieve lean and intelligent upgrading.
