Companies use Manufacturing Execution Systems (MES) to measure and control critical production activities, offering improved traceability, productivity and quality. MES controls process flow and reduces any chance of mistakes in the process. It gathers data every step of the way including who operated on the process, when it was done, how long each process took, equipment used for the process and other parameters . Further, it provides immediate data visibility for each work order, what the current work-in-progress items are and what stage they are in. MES systems serve numerous functions, such as equipment tracking, product serialization, labor tracking, inventory management, costing, task completion capture, and defect and resolution monitoring.

In order to fine-tune the production process and hone in on areas for improvement, a more detailed visibility is needed into these areas. This requires data capture in raw material tracking which leads to inventory management tracking; costing, WIP tracking, equipment and labor tracking. By effectively digitalizing data collection and controlling the entire system, an MES can realize manyfold improvement in manufacturing efficiency and productivity. Traditional MES systems employ barcodes and/or manual data collection during all the phases. However, the gap between physical flow of product and material and information flow in the MES is too large to provide accurate visibility.  Automated data capture via AssetPulse’s RFID tracking system transforms a traditional MES system into a Real-time MES system. 

AssetPulse’s RFID Tracking System

AssetPulse’s RFID tracking system automates data collection which includes reporting of raw material consumption in real-time, which in turn, allows for real-time updates of inventory; WIP Tracking, Tool, Process Instruction Document and Operator tracking. All this information feeds into the MES to afford real-time updates of the entire manufacturing floor including real-time status of all the jobs on the floor where potential issues crop up.

Without automated data capture from AssetPulse’s RFID tracking systems, updates to MES were being provided whenever it was convenient to enter the transaction into the system. E.g. When raw material for the next workorder is sent from ‘Supermarket’ (warehouse) to be staged at the assembly line, an ERP transaction might be completed as soon as it leaves the warehouse instead of when it actually arrives at the line. This may be done, because it is easier for the warehouse to complete this transaction since there might not be anyone at the line to receive the components at the staging area of the assembly line and then enter it into the system.

With AssetPulse’s RFID tracking system, a transaction is completed only when the inventory actually arrives at the line. Similarly, WIP status is captured in real time, i.e. exactly when the operator starts work on the WIP and when he finishes. In a traditional MES system, the start time may have been the completion of the previous operation, since that is the time the operator transacts in the system.

AssetPulse’s RFID Tracking system automatically captures the presence of all tools and equipment used on the line, travelers, documents and even the operators working at each workstation on the line. This allows alerts to be issued if and when incorrect tools, past-due calibration-equipment and documents are present. Further, it can flag operators and technicians present on the line, who haven’t completed the necessary certifications or training to perform the work.

There are numerous such examples where deployment of RFID can vastly enrich an existing MES system in order to gain maximum improvements in operational visibility, efficiency and improved quality.

The much-touted supply chain covers all activities that an organization performs from receiving raw material to delivering finished goods to the customer.  AssetPulse’ asset tracking solutions help you to use RFID in supply chain management and improve efficiency. The RFID tracking solutions play a vital role at almost every step of the Supply Chain, from receiving components or raw material at the receiving dock to delivering finished goods at the customer’s facility.

Changeover is an important component of lean manufacturing initiatives. It is the process followed when a manufacturing line is being changed over from producing one part to another or from completing one workorder to starting a new workorder. Changeovers can last from a few hours to days or weeks, depending on how extensive the changes to the line are. This process requires a lot of attention to detail and can be vulnerable to human errors.

Errors during the Changeover process can have lasting repercussions long after the finished goods leave the line. Due to the meticulous nature of doing a Changeover process, specially trained personnel are needed to perform these tasks, which can be costly. The ultimate goal of any manufacturing organization is to achieve the fastest possible changeovers without compromising on accuracy or quality.

Changeover complexity depends more on the process itself—factors such as number of internal steps, and validations required. Rapid changeover is critical for improving flow and maximizing throughput. RFID Tracking  can go a long way in automating this process, thereby minimizing or even eliminating human errors. Aside from error prevention, the Changeover process can also be expedited, thereby reducing overall downtime of the manufacturing line.

AssetPulse RFID Tracking solution has been implemented at various manufacturing facilities to automate the Changeover process. In industries that are strictly governed by compliance requirements, using the AssetPulse RFID Tracking solution also allows for automated record keeping. Details about Raw Material or Components including Part numbers, Lot numbers, Batch numbers, etc. can be automatically recorded at each point of the Manufacturing Line during Changeover. Equipment and Tools deployed during the Changeover process can also be automatically recorded.

Not only does the AssetPulse RFID Tracking solution help automate recording of tools, equipment and components deployed during the changeover process, but it can also help with validation and detecting errors. At every step, a validation can automatically be performed to ensure the right tools, equipment and components or raw materials are placed at the right location. On incorrect placement, the user can be alerted, so the error is rectified immediately.

Tracking with RFID can also help with enforcing the sequence of steps in the Changeover process. E.g. If the Changeover process requires pre-staging to be done, before the items are moved to the actual line, the AssetPulse RFID Tracking solution can ensure the right items are pre-staged and will throw up errors if they are moved to the line without the pre-staging step.

AssetPulse customers have seen a much-improved Changeover process, that is faster, more accurate and which allows the organization to meet compliance regulations with significantly lesser time and resources.