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MANUFACTURING|ASIA|

RFID-based Production Management of a Large Petrochemical Factory

Background
 
A large petrochemical factory in Taiwan has a massive production workshop, and product lines of a wide variety of models.  Its traditional paper process card type management not only involved complicated procedures and led to low efficiency, but also incurred more human interruptions, which did not satisfy high-performance management needs these days.
 
In order to optimize production management, improve production and management efficiency, and achieve paperless and intelligent production process management, this company decided to bring RFID technology into production process management, and chose to deploy Chainway UR4 fixed RFID reader and C72 mobile RFID reader at every critical node in the production process to attain intelligent management of critical node and product information in the production process.
 
Challenges
 
1, The production workshop is large and has plenty of production lines and products.  The management was complex and its workload was heavy.
2, Traditional management approach was labor intensive with paper-based information records and statistics, was was inefficient and prone to errors.
3, Managers could not timely and efficiently understand real-time status of each production process so correction was not performed in a timely manner.
4, It was difficult to perform statistical analysis of production information, which was unfavorable to the optimization of production management on the basis of the actual production status.
5, The nodes across the production could not communicate with each other in real time.  The lack of communication was unfavorable to the overall control of the production process and configuration optimization. 
6, Timely and accurate feedback information from the production line is essential.  In the past the data was only available when the production finished.  It was time-consuming and laborious, and even human errors were inevitable.
 
Solution
 
To solve these problems, the Taiwanese petrochemical company partnered with Chainway of Shenzhen and chose to deploy the Chainway UR4 fixed RFID reader and C72 mobile RFID reader to track and manage the production information used for the management of the various nodes in the production process.  Specifically, by deploying the Chainway UR4 fixed reader at each station in the production process, the relevant station RFID tag information is read automatically and the production information of each station is recorded in real-time when the RFID tag information is uploaded through the wireless network to the backend management system.  In addition, the station tag information can be read, queried and modified at any time using Chainway C72 mobile RFID reader.  The combined operation of fixed UR4 and mobile C72 has realized intelligent control of the entire production process.  Managers has been able to clearly understand the production process of each product through the backend system, thereby controlling production costs and boosting efficiency.
 
Outcomes
 
1, The deployment of Chainway RFID reader equipment has enabled automation of data acquisition and minimized errors from handwriting or bar code input.
2, Timely and accurate paperless information management has been achieved.  This achievement has greatly reduced production line downtime and improved production efficiency.
3, Before the products have been shipped, it has become possible to backtrack the cause of error and responsible person if quality management testing has found any differences in quality.  
4. The deployment has helped production managers make better use of labor, machines, tools, and components, avoid production loss and waste of resources, and improve asset utilization and productivity. 
5, The Taiwanese company has achieved their goals including real-time information management, flexible production management, accurate tracking and tracing and improved the level of automated production and productivity so that production management has become more flexible.
 
PDA configuration
 
Models: UR4, C72
Main feature: RFID
 
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