In the concept of ordinary people, the production of commercial vehicles is very different from that of cars. There should not be so much personalized demand. The demand for flexible manufacturing is relatively low. Basically, it is based on standard models with standard configuration. But in fact, in consideration of the competitive advantage in the fierce market competition, the users of commercial vehicles will also put forward a variety of personalized requirements for the ordered commercial vehicles, and the commercial vehicle manufacturers will try their best to meet such requirements. Therefore, there is little difference between the production of commercial vehicles and car production, just the size of the order quantity. At present, DAF, the largest commercial vehicle manufacturer in Europe, claims that every car they produce is a unique product customized to customers’ requirements. It can be seen that personalized customization has also become the trend of commercial vehicle production.
A few years ago, the state introduced a compulsory recall policy for automobile products. In order to adapt to the change of this environment, even the enterprises adopting the mass production organization mode must achieve the traceability of a single product, so the demand for information collection in the production process increases greatly. Information collection technology in the production process has more and more influence on production efficiency and production organization.
Based on this background, the application of RFID technology in commercial vehicle manufacturing enterprises is very similar to that in car manufacturing enterprises
Production process management (WIP)
RFID technology can be more automatic, real-time and reliable to take production progress information, making the production process and progress more visual, reducing the dependence on manual information collection, reducing costs and reducing errors. On the basis of the above more automatic and accurate information collection, commercial vehicle manufacturers can further improve their lean production management level and win the competitive advantage.
The improvement of production management by using RFID technology can be reflected in many aspects, such as:
With the cooperation of automatic production line, automatic selection of WIP production path — in the production process, products with different configurations often need to go through different paths. On the path bifurcation point, the WIP is identified to judge and select. Using RFID technology to identify WIP is the best solution.
Automatic verification of work in process and assembly materials – personalized production requires a high degree of cooperation between production and material distribution. Assembly materials must be delivered to the correct station at the right time and in the right order. However, in the actual production, errors are inevitable. Once the materials with errors are assembled on the WIP, a series of costs of error checking and correction will be incurred, and even the on-time delivery of products and customer satisfaction may be affected. RFID technology is often used to change error checking and correction to error proofing to reduce or avoid these unnecessary costs. RFID technology is used to identify WIP and current materials respectively, and the information system is used for comparison and judgment, which can effectively prevent errors, reduce the actions of operators that do not produce value-added, and avoid possible errors caused by manual intervention.
Automatic material pulling in production line lean production requires pulling material supply, which requires the material department to accurately and timely grasp the consumption of materials beside the production line. Through the more automatic RFID technology, the production process can be further visualized, which is conducive to the material department to grasp the production dynamics more accurately, reduce the safety stock and reduce the capital occupation on the premise of ensuring the material supply.
Collection of product traceability information collection of product pedigree information is the basis of product recall, and the most accurate information must be collected in the production process. Through RFID tags on materials and work in process, the information can be automatically collected one by one, which can reduce redundant actions of operators and improve efficiency; It also eliminates the possible errors of manual intervention and improves the quality of data.
Internal supply chain
The internal supply chain is an important part of the supply chain of automobile manufacturing enterprises. The operation level of the internal supply chain directly affects whether the production can be coordinated, balanced and efficient, It is of great economic value to improve the visualization of the internal supply chain (including the parts distribution process from spare parts warehouse to material preparation room to production line and the material handling process between various production processes).
RFID technology is used to install RFID tags on the material itself, such as engine, front and rear axle, frame and other important parts, or on the material handling container, such as material box, material rack and so on. RFID reading portals are set at all important checkpoints of the whole internal supply chain, or RFID reading and writing equipment is deployed on the material handling forklift, It can effectively improve the visualization of the internal supply chain, monitor the movement and distribution of materials in the internal supply chain in real time, and cooperate with the application of the above production process management. On the premise of ensuring the supply of production materials, it can effectively reduce the inventory level of material inventory and create benefits for the enterprise
TNT, which is responsible for the third party logistics business of auto parts in Europe, has successfully applied the RFID technology and products of INTERMEC, effectively improved the operation performance of delivering the right materials to the right station at the right time and in the right order, and significantly reduced the cost of logistics operation.
Automobile manufacturing enterprises have a large variety of automatic production equipment, the operation status of these production equipment determines whether the production can be carried out normally. Once some key equipment breaks down, it will force the enterprise to suspend production temporarily to eliminate it, which will cause great losses to the enterprise. How to effectively track these key equipment, ensure that they are fully maintained at the corresponding time, find and eliminate potential accidents in advance, and ensure their operation status, is an important work content of automobile production enterprises.
Using RFID technology to automatically track the key equipment, especially the key equipment directly related to production, excluding manual judgment and intervention can further ensure that these equipment are fully maintained, reduce losses and reduce costs.
Dailyme Chrysler company of the United States installed RFID tags on the brackets of its pickup production line to automatically track the operation status and maintenance technical records of these brackets, and achieved great economic benefits. Within four months, the cost saved was as high as $1 million, and all system investment was recovered, with an input-output rate of 345%.
In addition, RFID technology in commercial vehicle manufacturing enterprises can also be used in finished vehicle logistics and inventory management and after-sales service. In view of the space limitation of this paper, it will not be repeated one by one.
Use of commercial vehicles
For the users of commercial vehicles, RFID technology is also very useful. From a large number of practical application cases at home and abroad, it mainly includes the following aspects:
Freight yard management of logistics center
RFID tags are installed on transport vehicles and trailers, and the relevant information of vehicles is written in them. When the vehicle arrives at the gate of the logistics center, the reading and writing device at the gate reads and sends the vehicle information to the system. The system indicates the parking position of the vehicle according to the work plan, and notifies the relevant personnel to prepare for receiving the goods in advance. When a trailer needs to be parked in the freight yard, the parking position of the trailer can be quickly confirmed by the RFID tag on the trailer. When a trailer needs to be loaded and unloaded, the staff can directly find and confirm the trailer that needs to be operated according to the instructions of the system. In this way, the waiting time of air fare in the operation process can be effectively reduced, and the operation efficiency can be improved, Speed up the turnover of goods.
Permit management of operation vehicles
In many places, such as ports and airports, permission management is required for vehicles entering and leaving these areas. Vehicles without permission are not allowed to enter these areas. However, there is a natural contradiction between the strict pass inspection and the crossing efficiency. At the same time, manual inspection will inevitably lead to errors and management loopholes.
Using RFID technology in UHF frequency band to be able to read remotely, using RFID tag as electronic pass can effectively solve this problem. It can not only ensure the traffic efficiency of the crossing, but also plug the possible management loopholes and strictly manage it. This application has become a common management mode in many ports and similar occasions in our country. Otherwise, unless more vehicle access is built, it can not guarantee the timely assembly and evacuation of goods in the port area, which is bound to form a “pressure on the port”. RFID technology saves a lot of investment for these ports.
Measurement management of bulk cargo
Ports, power plants, coal mines, steel plants and other similar enterprises have a large number of bulk goods in and out all the year round. For example, the bulk goods arriving at the port, the coal consumed by the power plant, the ore and coke consumed by the steel plant, and so on. The usual management mode is to subtract the weight of the vehicles when they enter and leave as the actual weight of the goods arriving or leaving. In this way, it is difficult to avoid the management loopholes, the phenomenon of running, dropping and leaking is very serious, causing great economic losses to enterprises.
The same use of UHF RFID technology features, the RFID system and electronic measurement system are closely combined, the weight data obtained by the electronic scale is encrypted into the RFID tag, the RFID tag as the carrier of data carrying, all the processing completely eliminates the possibility of manual intervention, to a certain extent, plug the management loopholes. In addition, reading points can be set at the main divergent intersections of the internal roads of the enterprise to monitor the path of related vehicles, which can prevent other forms of cheating.
To sum up, in all aspects of the production and use of commercial vehicles, RFID technology has a lot of use, and can create huge economic benefits for users through these applications. Moreover, it can be considered that these applications are just the tip of the iceberg, and there are more applications to be found and mined.
Editor in charge: CT