Full lifecycle tracking of materials
Procurement and warehousing process: Suppliers paste barcodes (including material codes, batches, production dates, etc.) on materials according to MES system requirements. Warehouse personnel quickly complete receipt verification through barcode scanners, and the system automatically matches purchase orders to avoid manual input errors. For example, when electronic factories purchase resistors and capacitors, scanning the code can verify whether the material model is consistent with the order, and the storage efficiency is improved by 40%.
Production material requisition process: Operators scan the work order barcode to obtain the Bill of Materials (BOM), then scan the material barcode to complete material requisition verification, and the system updates the inventory ledger in real-time. A certain automotive parts factory reduced the material picking error rate from 5% to 0.3% through barcode material requisition.
Residual material return process: Unused materials are pasted with original barcodes and returned to the warehouse. The system automatically associates batch information to achieve traceability and reuse of residual materials, reducing material waste.
Accurate traceability of process path
Each work in progress is affixed with a unique barcode (such as a QR code) in the first process, and subsequent processes record information such as processing time, equipment number, and operator by scanning the code. For example, the gear shaft of a mechanical processing plant can be scanned to view the process parameters (such as cutting speed, furnace temperature curve) of the turning, milling, heat treatment and other processes that have been carried out in sequence, forming a complete machining history.
When there is a quality problem with the product, it can be traced back to the raw material batch, each process operation record, and inspection results through the finished product barcode. A certain food company has shortened the customer complaint handling time from 48 hours to 6 hours through barcode tracing.
Rapid issuance of production instructions
After the work order is generated through the MES system, a barcode work order containing product model, process route, delivery time and other information is automatically generated and printed and posted on the production line dashboard. Operators can scan the code to obtain task details, reducing the time required for paper document transmission. After introducing barcode work orders, a certain household appliance enterprise reduced production preparation time by 25%.
In the scenario of multi variety small batch production, when changing models, scanning the code to switch process parameters (such as the mold number and temperature setting of the injection molding machine), the system automatically calls the corresponding program, and the equipment adjustment time is reduced from 30 minutes to 10 minutes.
Data collection efficiency jumps
Replacing manual recording: Traditional paper work orders require manual filling of process completion time, equipment status, and other information, which can lead to issues such as blurry handwriting and missing information. By scanning codes to collect data, real-time performance has been improved by over 90%, and data accuracy has reached 99.9%. After canceling paper records, a certain electronic assembly plant saved 2 hours of data organization time per day.
Batch rapid recognition: At the end of the production line, a fixed barcode scanner is used to read finished product barcodes in batches. Within 10 seconds, the entire box of products can be registered for entry and exit, which is 20 times more efficient than manual registration.
Implementation of error prevention mechanism
Process sequence error prevention: It is set that the work in progress must follow the A → B → C process flow. If the operator attempts to operate process B without scanning the code to complete process A, the system will automatically intercept and prompt an error. A certain automobile assembly line has reduced the error and omission rate from 0.8% to 0.1% through this function.
Material anti mixing: In the SMT mounting process, the mounting machine verifies whether the electronic component model is consistent with the work order BOM by scanning the code. If the material code read by scanning the code does not match the system requirements, the equipment will automatically shut down and give an alarm. After being applied in a certain PCBA factory, the rework rate caused by mixing decreased by 70%.
Personnel qualification verification: Key processes (such as welding and testing) require operators to hold certificates to work. When scanning the code and logging into the system, the validity period of qualifications is automatically verified to eliminate the risk of unlicensed operations.
SUMMARY
With the rapid development of smart manufacturing, enterprises are facing unprecedented opportunities and challenges. In such a wave of digital transformation, how to enhance production efficiency and optimize management processes has become an important issue that every enterprise must address. As a key driver of industrial upgrading, smart manufacturing has become an important engine for industry development and improving enterprise competitiveness.
Against this backdrop, Xinhaizhichiao, with its profound technological expertise and rich industry experience, continues to provide leading IoT technologies, smart manufacturing solutions, and MES/MOM/APS systems to customers. Our solutions cover all aspects from the production site to enterprise management, helping businesses achieve more flexible and intelligent production models while improving production efficiency and reducing costs.
As a technological leader in the industry, Xinhaizhichiao continues to promote the deep integration of digital transformation and smart manufacturing, dedicated to providing the most competitive solutions for the global manufacturing industry. We will continue to adhere to the core concept of “Innovation Driven, Smart Manufacturing,” assisting our clients in standing out in the fierce market competition and staying at the forefront of industry development.
If you would like to learn more about smart manufacturing or discuss how to enhance your business efficiency through digital transformation, please feel free to contact us. Xinhaizhichiao is committed to providing you with comprehensive technical support and services, working hand in hand with you to embrace the new era of smart manufacturing.
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