In the discrete manufacturing industry, moulds and tooling are the ‘skeleton’ and ‘muscle’ of the production chain, Cependant, the traditional management approach has long faced asset loss, loss of control of the state, maintenance of inefficiency and other pain points.The depth of application of RFID technology, by giving moulds and tooling a ‘digital identity’ is reconstructing the intelligent management paradigm of manufacturing resources. The deep application of RFID technology, by giving moulds and tooling ‘digital identity’, is reconstructing the intelligent management of manufacturing resources paradigm.
The traditional management dilemma: from ‘asset loss’ to ‘efficiency black hole’
1.Mould management pain points
- Blind status: In injection moulding, stamping and other scenarios, the number of times moulds are used and the degree of wear and tear rely on manual records, and are prone to overloaded operation.
- Time-consuming mould adjustment: the time for finding moulds in large factories accounts for 30% of the production preparation time, and even delays the delivery in case of emergencies.
2.Tooling Management Challenges
- High-frequency replacement is easy to make mistakes: automotive welding production lines change fixtures dozens of times a day, and manual checking of models is easy to make mistakes.
- Difficult to predict the life: outillage, fixtures and other fixtures have hidden loss, and sudden failure leads to downtime loss.
A construction machinery enterprises have been due to confusion in the management of fixtures, the average annual scrap value of more than 5 million yuan of fixtures, the problem urgently needs technical intervention.
Technologie RFID: to build the ‘Internet of Things perception network’
1.The core ability to adapt to industrial scenarios
- Resistant to harsh environments: anti-metal tags are resistant to high temperatures (300 ℃ +), anti-oil, suitable for stamping, casting and other harsh environments.
- Batch identification: Fixed readers can identify all RFID tags in the workshop in seconds, increasing efficiency by 10 fois.
- Dynamic data updating: Tags store process parameters, maintenance records and other information to achieve ‘one item, one file’.
2.Flexible deployment modes to suit the needs
- Mould embedded tags: Encapsulate tags on the non-working surface of the mould to avoid affecting the moulding surface.
- Workpiece suspension tags: designed for fixtures, outils, vibration-resistant tags to ensure long-term reading stability.
Intelligent application scenarios: from ‘passive response’ to ‘active control’
Scene 1: full life cycle tracking
- Transparency of mould flow: Moulds are automatically recorded in and out of the warehouse through RFID channel gates, combined with AGV scheduling system, mould finding time is shortened by 70%.
- Visualisation of tooling status: Installation of readers on CNC machine tools automatically records the number of times the tool has been used and the wear data, increasing the accuracy of life prediction to 90%.
Scene 2: Intelligent Maintenance and Error Prevention
- Predictive maintenance: An automotive factory discovered the wear trend of welding fixture positioning pins through RFID data, and replaced them in advance to avoid the loss of 2 million yuan in line stoppage.
- Error-proof verification: RFID readers automatically check the matching of workpiece models and work orders, thus reducing 95% of clamping errors in an electronics company.
Scene 3: optimal allocation of resources
- Utilisation analysis: A home appliance company found that 10% of the moulds contribute to 50% of the production capacity through RFID data, and the overall efficiency is increased by 18% after targeted expansion.
- Shared inventory management: cross workshop RFID data linkage, tooling idle rate reduced by 30%, reducing the cost of repeated purchases.
Data-driven management upgrade
Seamless integration with MES/ERP
RFID data is synchronised to the management system in real time, automatically generating maintenance work orders and updating inventory status, eliminating information silos.
Digital twin empowered decision-making
Based on RFID data to build a virtual model of the mould and tooling, simulate the process optimization scheme, reduce the number of trial moulds by 40%.
