In the field of industrial manufacturing, mould as a high-value core asset, its management efficiency directly affects the production quality, cost and delivery cycle. Under the traditional manual management mode, mould positioning is time-consuming, status is difficult to trace, maintenance depends on experience and other problems occur frequently, и RFID (Радиочастотная идентификация) technology by giving the mould ‘digital life’ to achieve from ‘artificial inefficiency’ to ‘intelligent and accurate’ management changes. ‘Intelligent and accurate’ management changes. The following is the analysis of its core advantages:
Автоматическое отслеживание: second positioning, eliminating the ‘find the mould’ потеря
In the traditional mode, workers need to rely on paper ledgers or barcodes to manually find the moulds, the average time-consuming 20-30 минут, and due to label defacement, misplaced ‘missing’. The traditional mode, workers need to rely on paper ledgers or bar codes to manually locate the moulds, which takes 20-30 minutes on average, and the ‘missing’ problem caused by tag defacement and misplacing is common. RFID completely changes this situation through non-contact automatic identification:
Real-time positioning of the whole scene: Embedding metal-resistant RFID tags in the moulds’ body (temperature resistant -40℃~200℃, such as NXP UCODE 9 Чипсы), together with the Warehouse door readers (single reading 200 + tags within 30 m) and stationary readers, the system real-time synchronisation of the mould position (accuracy ± 0.5 m), the search time is compressed to 30 секунд. After the application in an auto parts factory, the downtime caused by mould searching was saved over 2,000 hours per year, which is equivalent to a 15% increase in production.
Path full traceability: automatically record the time of the mould in and out of the warehouse, the flow of the track (such as ’14:00 from the injection moulding machine No. 5 station transferred to the maintenance area’), to completely solve the problem of misplaced moulds, lost problems, the inventory accuracy rate increased from 85% Кому 99.9%.
Сбор данных в режиме реального времени: the whole process digital, goodbye to the ‘data island’
RFID through automated data collection to build accurate digital archives:
Real-time synchronization of production data: station readers automatically capture the mould Real-time synchronisation of production data: the workstation reader automatically captures the mould uptime, cumulative processing times, pressure/temperature and other parameters, and uploads them to the MES system in real time to form ‘mould – Оборудование – процесс’ correlation data, which provides a real-time basis for capacity analysis. After the deployment in an electronics factory, the data collection efficiency increased by 5 раз, and the omission rate was reduced to less than 1%.
Maintenance records are permanently archived: maintenance personnel scan the labels with handheld terminals to automatically retrieve historical maintenance files and update maintenance logs in real time, forming a complete equipment health file, solving the problem of ‘loss of maintenance experience’ and improving maintenance efficiency by 60%.
Intelligent error prevention: zero tolerance of ‘misuse risk’, guarding the bottom line of quality
Misuse of moulds (Например, using the wrong model, using over-specification) is an important cause of product defects, and the leakage rate of the traditional manual calibration is about 10%. RFID achieves precise error prevention through the digital calibration mechanism RFID achieves precise error prevention through digital calibration mechanism:
Process matching automatic calibration: the system presets the matching rules of moulds, equipment and materials, and when the moulds are misused, the reader immediately triggers audible and visual alarms and locks the equipment.
Compliance mandatory control: in the aerospace and medical devices and other fields with stringent requirements on quality, the RFID tags store information such as calibration certificates and compliance certificates of the moulds, and can be used for production. RFID tags store information such as mould calibration certificates, compliance certificates, и т.д., and automatically calibrate the expiry date before production to ensure that each batch of products can be traced back to meet the auditing requirements of standards such as IATF 16949. Iv.
Профилактическое обслуживание: From ‘Putting Out Fires After the Fact’ to ‘Preventing Them in Advance’
Traditional timed maintenance (Например, ‘every 500 uses must be serviced’) tends to lead to ‘maintenance of the mould’. Traditional timed maintenance (Например. ‘every 500 uses must be maintained’) is prone to ‘over-maintenance’ or ‘under-maintenance’, while RFID achieves accurate maintenance through data-driven intelligent operation and maintenance:
Lifespan prediction model: based on LSTM algorithm Based on the LSTM algorithm, it analyses the cumulative processing times of moulds, vibration spectra, и т.д., and warns of component fatigue (Например, wear of guide pillar, spring failure) 3-5 days in advance, and automatically generates maintenance work orders. After the application of a home appliance enterprise, the number of sudden failure downtime was reduced by 60%, maintenance costs dropped by 25%, and the average life of moulds was extended from 8,000 times to 12,000 раз.
Dynamic Maintenance Strategy: Say goodbye to the ‘one-size-fits-all’ maintenance cycle, adjust the maintenance plan according to the real-time working conditions (Например, shorten the maintenance interval for high-frequency use of moulds), and thus reduce the redundant maintenance cost by 30% for an automotive mould factory.
