RFID based kanban automated ordering system

In accordance with the research studied, a prototype system of RFID-based integration application with the background of a discrete production workplace will be created. The system's hardware included a fixed RFID reader with a working frequency of 915MHz, a display terminal device with a 13.56

Project Title

RFID based kanban automated ordering system

Project Area of Specialization

Robotics

Project Summary

In accordance with the research studied, a prototype system of RFID-based integration application with the background of a discrete production workplace will be created. The system's hardware included a fixed RFID reader with a working frequency of 915MHz, a display terminal device with a 13.56MHz RFID reader for scanning staff identity cards, a management terminal computer, a server, and network equipment. We employed UHF tags based on the ISO 18000-6C standard (used for labeling WIP goods and pallets) and HF tags based on the ISO 15693 standard (used as the identity cards of staff). The primary functions are as follows: RFID-based Kanban management, which put the Kanban management process outlined in Part 1 into action. Manufacturing process supervision, which can obtain WIP item, task, and manufacturing unit processes information.

• RFID-based Kanban management, which actualized the Kanban management process.
• Manufacturing process supervision, which can obtain WIP item, task, and manufacturing unit process information.
• Resource state supervision, which can display the status of WIP goods, personnel, and manufacturing units at any moment.
• Production data statistics and analysis can provide data on productivity and output as well as identify problems such as bottlenecks in the manufacturing process and unreasonable resource distribution.

Project Objectives

The main objectives of the project are listed below;

• To develop a simplified and useful model.
• To equip industries especially SMEs with these comprehensive tools to enhance their performance.
• To understand the mechanism of an RFID system along with the Kanban system.
• Trying different integrating techniques between RFID and Kanban and evaluating different results with it.
• An application for monitoring and synchronizing RFID data with live and updated record keeping will be developed. 
• To solve the problem for newly established and developing business models by assisting in daily operational activities.

Project Implementation Method

An industrial production line with many workstations will be considered in this project. For JIT products, each workstation uses a two-bin Kanban inventory approach. Because the part requirements and production processes of semi-finish and finish goods change, each workstation uses a different number of parts. Each one is kept in its own bin in the designated storage areas near each workstation. If the considered industry produces several quantities of products every day, there is always a varied requirement for each unique part. The production process begins with the first workstation and the product of each workstation is moved to the next to continue the production process. Consider that each final product is made up of 600 separate pieces, 200 of which are JIT parts. This means that around 400 JIT parts are always required across the entire production line. However, this number of parts will be required eventually, but having them available in the line wastes money and space.

Considering that there are various production lines, it can be noticed that notice that the quantity of additional JIT components held in the storage area is increasing accumulatively by employing the Two-bin Kanban system. However, by utilizing RFID-based Kanban and production unit theory, the correct amount of parts are always present at the correct location. And there is no waste of money or extra space occupied by having unneeded parts in the manufacturing stations, production lines, or industrial areas in general. As previously stated, each production line requires a total of 200 JIT parts. However, the difference between the two scenarios is clear: the stored JIT parts in RFID-based inventory can be cut in half when compared to two-bin inventory in the best-case scenario. And it makes a significant difference in the total amount of JIT parts kept across the entire industrial region.

Benefits of the Project

This project will result in

• The environmental wastage will be reduced as a result of limited transportation by implementing this model.
• operational performance of the organizations will be Increased.
• Exact control of the flow of goods.
• Exchange of information in real-time
• Continuous, simple order and data transfer.
• No need for manual data entry.
• Improved warehouse and inventory management.
• Identification of demand fluctuations and peaks.
• No extra storage space is required.
• Fast conversion without changing. existing processes.
• It also is not like complex technologies, No employee training necessary for this.

Technical Details of Final Deliverable

The running environment for the smart Kanban system will be built. In this system, the dynamic information of Kanban will be created and updated with the series of activities of operators during the manufacturing execution. Therefore, the activities that occurred between the operators and the containers play an important role to trigger the information flow of smart Kanban. They could be briefly described as follows:

1. When the production operator comes to the work center, his staff card will be detected by the RFID reader installed there.
2. The RFID reader captures the information from the staff card of the production operator and updates the corresponding status items immediately. Then, the reader sends this information to the RFID-based Kanban system via wireless technologies to retrieve the corresponding information of this staff. A warning message will be popped up on the display of the work center if there is no task to be executed by this operator.
3. The production operator will prepare for production if the display of the work center shows the production command.
4. Before production, there must be an empty container placed at the output buffer area of the work center. The container is used to put the semi-products finished by the current process. The information of the container will be detected and captured by the same RFID readers installed at the work center as soon as the container arrives at the output buffer area. Then the information of the smart card of the container will be automatically updated according to the process data.
5. A production Kanban will be created and displayed according to both the current process information and the number of production Kanban. When a new production Kanban is created, the total number of the production Kanban of this process will be subtracted by 1.
6. The production operator produces products according to the information of the production Kanban. Once the production activity starts, the container with materials will be placed at the input buffer area of the work center. Similarly, the smart card of the container is detected and captured by the RFID reader installed at the work center. The XML-based information is updated by the system and the number of withdrawn Kanban of the materials of the process will be increased by 1.

Steps (d); (e) and (f) will be repeated until all the tasks are finished

Final Deliverable of the Project

HW/SW integrated system

Core Industry

Manufacturing

Other Industries

Transportation , Health

Core Technology

Robotics

Other Technologies

Artificial Intelligence(AI), Others, Big Data

Sustainable Development Goals

Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and Production

Required Resources

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