RFID gate
Traceability
Paperless production
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The determination of order progress is laborious.
If order documents that are only available in analog form have to be exchanged or prioritized, the search takes a lot of time.
Confirmations that lead to retrograde material postings are only made at the end of a production line.
The distribution of parts lists for production is organizationally complex and error-prone, which leads to incorrect assignment of orders to a work center.
This is what our customers say
Away from paper, towards digitalization - that was our challenge. Our intention was to do away with the printing of production papers in production. The worker can now retrieve data individually for each motorhome. The resulting reduction in costs and the advantage of always being able to provide the worker with up-to-date data, such as assembly instructions, drawings, parts lists or graphical representations of articles, online, have led to a significant increase in productivity and a further improvement in quality. Together with SIGMA, it was possible to set up our ROBI information system. An exchange of knowledge and good mutual cooperation led to the successful integration of the system into production. This enables Carthago to continue to stand uncompromisingly for the highest quality, ideas and innovation.
Technical management
Carthago d.o.o.
By implementing the GRAIDWARE® Track and Trace system, we have complete control and transparency over our production process. The system enables us to track every step in the manufacturing process of safety-relevant body parts and also to continuously optimize quality and efficiency. The stored data opens up enormous potential for us, not only in terms of improving quality, but also for future developments and innovations in our production.
Marc Schweizer
Business Development Manager, fischer group
Why you should introduce paperless production
Optimization of the material flow
The integration of RFID technology improves efficiency in the movement of goods within the warehouse.
Complete traceability
This leads to improved production planning and control, thereby minimizing costs.
Reduction of the error rate
As human errors are avoided when entering data, the accuracy of the data is increased.
Efficient and transparent production
Increased transparency along the entire value chain enables companies to view the status of their production at any time, react quickly to market changes and remain competitive.
Improved warehouse management and control
Real-time data transmission using RFID tags enables automatic and accurate recording and updating of stock levels.
Environmental protection
By minimizing paper consumption and other resources, companies can better achieve their sustainability goals.
RFID technology as the key to paperless production
Technologies and technical requirements
RFID technology is a central component of our paperless production solution. It enables the complete digitalization and optimization of the information flow in production. Instead of physical paper documents, all relevant data is recorded via RFID tags and transmitted to central systems without contact. This enables contactless identification and tracking of objects in real time, making the entire production process more efficient and flexible. Our solution automates data capture, reduces manual input errors and saves valuable time - a decisive step towards increasing overall efficiency in production.
Hardware
The identification of products or load carriers with RFID tags, which store information and transmit it wirelessly to a reader, plays a central role in paperless production. These transponders are attached to workpieces, machines or containers. As soon as an RFID tag comes within range of a reader, the information stored in the tag is read and transmitted to the production system. This enables the seamless recording and tracking of objects at critical points in production without the need for physical barcodes or manual input.
We also use IoT sensors that record and analyze data, such as temperature, pressure or humidity, directly from production. This allows us to react immediately to deviations in target values specified by the ERP system and comply with documentation requirements. IoT sensors also enable quality assurance and efficiency improvements.
We use terminals and mobile devices to provide order information at the respective workstations (QS, production data acquisition, and forklift terminal). These devices ensure that employees always have access to up-to-date, product-, work process- and workstation-specific information. This means that customer-specific orders can be adapted flexibly and without time-consuming searches. The up-to-dateness of the data makes it possible to integrate changes into the production process in real time.
Software
Our software solution, the AutoID/RFID middleware GRAIDWARE, plays a central role in paperless production. It enables access to order data from ERP or production planning systems and distributes product-specific parts lists and work processes flexibly to the individual work centers or stations. This functionality is particularly advantageous for the production of very small batch sizes down to batch size 1, as it enables a high degree of flexibility and efficiency.
Compared to traditional ERP and MES solutions, the SIGMA solution focuses more on tracking and providing information via RFID. Integration into existing customer systems is particularly easy thanks to the availability of PDA components and the use of OPC UA for data exchange. A combination of different identification technologies, machine connections and data exchange with ERP systems is often used to ensure seamless communication between the systems and optimal use of production data.
The SIGMA solutions can be used in the cloud so that they can be used across multiple locations. When using cloud-based ERP solutions, an on-premise installation of the GRAIDWARE solution is also possible for paperless production, so that production can be maintained even if the ERP system fails. As soon as the connection is re-established, the production data is synchronized with your ERP system.
Optimized processes: Areas of application for paperless manufacturing
Production planning and control RFID enables real-time monitoring of production processes.
Document management RFID technology eliminates the need for physical documents in production.
Traceability of components RFID enables components to be uniquely identified and tracked throughout the entire production process.
Machine maintenance and servicing RFID enables machines and systems to be tracked seamlessly.
Collection of performance data RFID enables real-time monitoring of components and production facilities, automatically recording and analyzing performance data such as availability, performance, and quality.
Order management RFID technology enables you to track orders digitally in real time throughout the entire process.
Quality management RFID enables automated quality control directly on the production line.
Logistics In logistics, RFID ensures seamless tracking of materials and products throughout the entire supply chain.
You can find valuable tips for implementing paperless production in our guide.
Comparative illustration: Traditional vs. paperless manufacturing
Aspect | Traditional production | Paperless production |
Order management | Manual administration with high effort and susceptibility to errors | Digital and automated order tracking in real time |
Document management | Physical documents, time-consuming searching and distribution | Digital documents, instant access and easy distribution |
Material tracking | Manual recording, often only at the end of the production line | Automatic, seamless tracking in real time |
Quality management | Manual checks, high risk of errors | Automated, real-time quality checks |
Flexibility | Limited flexibility, adjustments are time-consuming | High flexibility, quick adaptation to customer requirements |
Error rate | Higher error rate due to manual processes | Reduced error rate through automation |
Traceability | Difficult to track, especially in complex processes | Seamless, simple traceability thanks to digital systems |
Environmental impact | High paper consumption | Reduced paper consumption, sustainable approach |
Customized manufacturing: Flexibility through digitalization
In an increasingly personalized world, the ability to manufacture products in small batch sizes according to individual customer requirements is becoming a decisive competitive advantage. Strategies such as one-piece flow, batch size 1 manufacturing, and the make-to-order principle are examples of production methods that offer maximum flexibility while meeting the requirements of modern, efficient manufacturing.
One-piece flow ensures that each product is manufactured in a continuous, seamless process. Instead of producing large quantities of a product in batches, each part is manufactured individually and in a single pass. This significantly reduces throughput times and minimizes inventory, as only what is actually needed is produced. In a digital manufacturing environment, this approach can be optimally implemented through real-time data collection and control. Each station in production is precisely coordinated, which reduces errors and increases the quality of the end products.
VELUX Group success story
What were the challenges?
The traditional way of working with production and order papers reached its limits due to a lack of flexibility, the large number of product variants, batch size 1 production and the shortage of skilled workers.
How have our solutions helped to improve efficiency in the company?
At the VELUX plant, UHF RFID technology is successfully used in final assembly in combination with the RFID middleware GRAIDWARE LOS. Window frames and sashes are fitted with RFID transponders, allowing them to be uniquely identified throughout the entire assembly process using RFID readers and seamlessly tracked right through to goods issue.
The system ensures that every worker at the assembly workstation receives the relevant information for each product and variant. This ensures that the assembly process is efficient, precise and tailored to the specific requirements of the product. This leads to increased product quality and optimized workflows in final assembly.
What other benefits can VELUX derive from the SIGMA solution?
By systematically collecting data on actual cycle times in the production process, the company gains valuable information on which product types should preferably not be produced in quick succession. For example, the analysis shows that cycle time overruns occur more frequently for certain product types if they are produced too close together. These findings help to optimize production planning and avoid bottlenecks.
In addition, the transparency of system downtimes and the individual recording of defects and errors by employees ensures that the causes are analyzed precisely. With the help of Pareto evaluations, the most frequent problems can be quickly identified and eliminated in a targeted manner. This enables efficient problem solving and makes a significant contribution to reducing downtimes and increasing overall productivity.
FAQ: Frequently asked questions about paperless production
Paperless manufacturing is fundamentally changing how companies structure and optimize their processes. The use of digital technologies replaces paper-based processes, which brings numerous advantages.
When paperless production is introduced, all important data and information is recorded, processed and forwarded digitally. This data is available to different departments in real time, which improves communication and ensures a smooth flow of information. Work instructions can be transmitted digitally to employees and they can enter the status of their tasks directly into the system. This leads to a reduction in errors and a higher level of quality assurance.
The main objectives of paperless production include numerous strategic advantages that optimize the entire manufacturing process. The focus is on increasing efficiency, as digital processes minimize manual steps and automate workflows. This also leads to a reduction in costs, as fewer resources such as paper and printers are required and error costs are reduced.
Another important aspect is the faster response time, as information is available in real time and decisions can be made more quickly.
Transparency and traceability are ensured by the seamless digital recording of all production data, which enables better control and traceability of processes. This also results in greater flexibility and scalability, as systems can be easily adapted and expanded to meet changing requirements.
Yes, RFID technology can make a significant contribution to improving production quality. By automatically and seamlessly capturing data in real time, RFID enables precise monitoring of each individual production step. Sources of error that could arise from manual data entry are minimized as the information is recorded automatically and contactlessly.
In addition, RFID technology allows quality checks to be integrated directly into the production process. This means that deviations or defects can be detected and rectified immediately before the product reaches the next production step. The seamless traceability of components also makes it possible to monitor and document quality throughout the entire production process. This not only leads to higher product quality, but also to a reduction in rejects and rework.
RFID technology, especially our AutoID/RFID middleware GRAIDWARE, is designed to integrate seamlessly into existing production systems. A key component of our offering is the ability to establish a direct connection between GRAIDWARE LOS and the control processes of the individual system components using the OPC-UA interface. This enables comprehensive transparency and control over the production process. Our solution also supports integration into an existing ERP system, which enables optimum organization and management of production processes.
We will be happy to present solutions for your industry and your processes. Talk to the specialists for SMEs.
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