RFID technology streamlines production

RFID is the same wireless technology that drives the microchip in your pet dog or the security tag on your key ring. Increasingly, it is being used in innovative manufacturing, supply chain and security solutions.  This technology is applicable to a wide range of industries including: automotive, food and beverage, pharmaceutical, TCF and general manufacturing.

In this project, RFID technology was used in combination with Siemens PLCs to deliver an integrated, dependable and operator-friendly system.

ICT Control Systems Engineer, Shaun Van Beek explains. “Our client was seeking to error-proof the assembly line, to improve quality and to reduce wastage and re-work. This high volume production line assembles diverse engine types, each with its own variable in terms of process and components. The aim was to provide the capacity to swap from one engine type to another during the course of the shift, without impacting product quality or productivity.”

With the new system, each engine block is fitted with an RFID tag at the beginning of the line. The tag is written with all the information about the type of engine and the various components required for correct assembly.

As each engine unit reaches an operator station, its tag is automatically scanned and the operator is presented with the appropriate assembly data via a touch-panel screen. The major components handled by the operator are separately bar-coded (some with 3-dimensional codes) for identification with hand-held or fixed scanning devices.

“We have integrated an interlock system so that an engine block will not move to the next operator station until the prescribed parts are confirmed as correct,” explained Shaun. “There is even a facility to check the torque of the assembly guns, ensuring the nuts are tightened correctly at each operator station.”

The system also provides capacity for downstream notice of subsequent production needs, meaning that an operator can access the system to check the upcoming engines so that he/she can prepare the necessary components before the next unit reaches that station.

An in-built security feature gives password access to the various functions of the system, so supervisors can track every engine, bypass an interlock or reassign engine types, as required according to production needs.

In a production environment such as this, minimising down-time is critical. “We designed the system over a 3-4 month period and had much of it pre-fabricated and ready to go so that we could complete the commissioning work during a Christmas shut-down period,” said Shaun.

The end result has been a very successful project for ICT and one which exceeded the expectations of this very satisfied client.