Rfid Goods Seperator

8/3/2019 Rfid Goods Seperator

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Series Production of Single Pieces

Automatic Identification optimizes the versatile Production in the Electrical Industry

Technologies for the automatic identification play an important role in the efficient, high-quality production

of diverse product versions. For this, the electronics manufacturing plant of the Siemens AG in Amberg,Germany, employs both 2D codes and radio frequency identification (RFID).

At the Amberg electronics manufacturing plant, over 1,000 employees manufacture the numerous modules of the successful controller family SimaticS7

The Amberg site is considered the crown jewel of the Siemens group: For many years, over 1,000 employees havebeen making the numerous modules of the successful controller family Simatic S7. The main goal of the productionengineers: The quality of the products. After all, the Simatic components are used worldwide by Siemens customersin countless factories for controlling production sequences device failures would result in a production stop and thusconsiderable costs. At the same time, the Amberg plant has to of course operate at maximum efficiency to remaincompetitive at the international level. This becomes all the more difficult as the Simatic family now offers a greatvariety of products for different applications. The task is: Organize the production sequences in such a way so that aneconomical production is possible despite the large number of variations.The solution lies in a process flow that is fully aligned with the product variation: We do not consider the products asmass-produced goods, rather each product is treated as a unique specimen, explains Bernhard Streber, responsiblefor identification technology at the electronics manufacturing plant. This is made possible by a flexible productionconcept, in which each machine and each workstation can process a large number of different products starting

with flexible mounting machines for the manufacture of the printed circuit boards and ending with packagingworkstations, where for each individual product, the accessory items enclosed, e.g., cables, documentation, softwareCDs, are shown on the monitor and their removal from the storage bins is checked.

Optical Codes as Key TechnologyTo control this complex system, the identification of each product at every work step is necessary. For efficiencyreasons, this can only take place automatically. In doing so, the electronics manufacturing plant primarily relies onoptical codes. Encoded are the unique specimen number of each part, intermediate product, and final product. Apowerful Oracle database then provides all information required to the individual workstations in real -time by meansof a Web service. In addition to the actual production information, e.g., the parts list for a product, this data alsoincludes extensive test specifications and reference values for the quality assurance. The codes are printed by inkjetonto adhesive labels, or lasered on directly. Even parts from suppliers receive a plant-internal unique specimennumber at the incoming goods department, says Bernhard Streber. This is easier and more target -oriented than toagree on a number standard with the changing, worldwide located suppliers of the plant.While the simple bar code used to dominate, this role has now been assumed by the 2D code (Data Matrix). This

encoding type impresses with its comparatively high information density, robustness against errors, and little spacerequirement. For instance, it is possible to uniquely mark even the smallest of modules such as connectors or printedcircuit boards. Another advantage: Since the 2D code is considerably smaller than a bar code, it can also be appliedmuch faster by laser. As a result, we were able to lower the cycle time by 2.5 seconds per product, explains Streberthe significant productivity increase in the electronics manufacture.Besides the actual production control, extensive quality data for each product is also collected via the small codes.For each device leaving the factory, the Amberg staff can precisely retrieve the parts from suppliers installed, theproduction time, the measurement results, and much more. These audit trails are of particular importance in safety-critical components to prove the error-free production in case of doubt. In addition, the data collection also helps inoptimizing the quality, since certain error patterns can be detected at an early stage.


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Optimization of the Read ResultsFor reading in the codes, the electronics manufacturing plant mainly uses in-house camera systems: The SimaticVS130-2 is something like the workhorse in the plant. Thanks to the separate arrangement of sensor head andinterpretation unit, the camera system can be installed even in the cramped machines close to the conveyor. Theseamless integration into the Simatic controllers makes the engineering especially quick and easy. The mostimportant advantage, however, is the high read quality of the Simatic VS130-2, since any malfunction would lead to a

production stop. The good results can also be attributed to the cooperation of the Amberg plant with the cameradevelopers: We already tested the cameras prior to the product launch, and provided real code images for thesystem test, reports Streber. Altogether, the electronics manufacturing plant employs over 50 cameras of the modelSimatic VS130-2 in the production.Next to optical codes, the identification by radio is also increasingly used in the Amberg electronics manufacturingplant. Radio Frequency Identification (RFID) is employed wherever specific circulating goods such as workpiececarriers or soldering frames need to be identified. The advantage: Since the data storage media (transponders) canbe written to as often as desired, the radio chips can be reused almost an unlimited number of times. For instance, atthe final assembly of the modules, the parts list is written to an RFID transponder affixed to the workpiece carrier,which is read out at every assembly station. Only after the device number has been lasered onto the enclosure is the2D code used for the identification. RFID is also employed at the machines for the selective soldering of modules.Each soldering frame as well as the hold-down fixture required for the product is equipped with a Simatic RF300transponder. When inserted into the machine, the soldering frame and the hold -down fixture are indentified by areader; a comparison with the production program immediately uncovers incorrectly positioned soldering frames orhold-down fixtures. Here, RFID has a lead over other technologies, since the transponders offer a high resistance to

heat and detergents. The setup inspection is of course only a small RFID application, but such applications, too, areimportant elements for the comprehensive quality assurance of our products, says Bernhard Streber.

RFID Use in the Supply ChainAccording to Streber, the potential for RFID applications in the plant has not been fully tapped yet. In particular theautomation of the supply logistics presents a promising field of application. For instance, it is being considered topermanently mark the individual units manufactured with RFID to ensure a clear tracing also in the distributionlogistics; a use that the colleagues of the Siemens telephone manufacturing plant in Leipzig, Germany, have alreadyimplemented. There, each device of the OpenStage line is now equipped with an RFID radio chip. The problem inAmberg: The Simatic components are constructed very compact resulting in different device component possiblyshielding the RFID transponders. But the resourceful engineers of the Amberg plant will surely come up with anothertrick here to get a step closer to the vision of an automatic product identification for the entire lifecycle.

Automatic IdentificationWhether 2D codes or Radio Frequency Identification (RFID): Both marking/identification systems convince with their

high data integrity, have proven themselves in many applications even in harsh industrial environments, and can beemployed for diverse tasks in the production and logistics. For both technologies, Siemens supplies a wide range ofdetection systems, which are fully integrated into the Simatic automation landscape.The 2D code is an optical recognition method and thanks to its structure especially suitable for the fast, safe, andclear acquisition. It offers easy recognizability through its boundary patterns as well as security through special dataencryption with data redundancy. As a result, even partially dirt-contaminated or damaged information can bereconstructed automatically.RFID, on the other hand, is based on radio waves and thus particularly insensitive to dirt contamination. Thetransponders provide a large storage capacity of up to 64 KB and can be written to virtually an unlimited number oftimes. Thus, extensive production and quality data can be stored directly at the product or workpiece carrier. Thanksto the long range when utilizing the UHF frequency band (865 MHz), logistics applications, too, increasingly attractnotice.

Siemens RFID Solutions

Small, Compact, and Reliable

Solutions for industrial identification are being used increasingly wherever there are

requirements for flexibility in production, continuous transparency in the flow of goods through the supply chain, efficient

asset management, or tracking and tracing of products. With the Simatic RF200, there is now an identification system that
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opens up new application possibilities. moreSeries Production of Single Pieces

Technologies for the automatic identification play an important role in the efficient, high-quality

production of diverse product versions. For this, the electronics manufacturing plant of the Siemens AG in Amberg,

Germany, employs both 2D codes and radio frequency identification (RFID). moreAuto ID Automatic Identification in automated Processes

Automatic identification aids in the safe detection and control of the flow of materials and goods in the production and in t he

goods distribution as well as in the service area and in the inventory management. Manual entries, format changes and

paper records in contrast are too susceptible to errors. moreThe task is decisive

Radio Frequency Identification (RFID) applications are becoming more and more diverse. In

industry, besides pure production controls, other tasks, such as asset management or the optimization of supply chains are

increasingly being handled by RFID systems. moreThe new Intermediate Layer

The main task of RFID systems is the automatic acquisition of goods and objects. The potential

of this new technology, however, is only fully tapped, if the read data is intelligently used and networked. moreIncreased productivity through RFID

Production managers and suppliers in the automotive, metal, and electrical industries are under

particularly high pressure: on one hand, they must lower costs continuously; on the other hand, they must comply with

especially high quality standards. moreSynchronization with RFID

Time and time again, a wide variety of models, product liability and the constant demand for

increasing efficiency pose challenges to manufacturing companies. The flow of materials has to be synchronized and quality

data be collected, while simultaneously, the cycle times and the downtime risk have to be lowered. moreSynchronous with reality
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4/9

A modern factory is unimaginable without comprehensive IT systems. Manufacturing Execution Systems (MES) are

currently completing many tasks faster and with greater precision than it would be possible with manual processes. moreWireless labels control production

Radio frequency identification (RFID) has been proving its worth for many years now in factory

automation when it comes to reliable identification of workpieces in order-related production. moreSimple control of complex processes

Numerous questions occupy those responsible for logistics and production today more than

ever not only in the automobile sector. Radio frequency identification brings light into the darkness. moreTransparency for lower costs

Burger with ketchup: Where were its ingredients sourced? Are they still fresh? 79.99 euros for a

bottle of sparkling wine: And is it "genuine"? The food and beverages industry can answer these questions on the basis of

batch separation, tracking & tracing, and further optimization of production and logistics. Automatic identification with RFID

and 2D codes will help here. moreReliably identified

Product identification was already utilized by stonemasons of the antiquity. In manufacturing

plants, it increases their flexibility and economic efficiency. moreUHF Technology ready for Industrial Applications

The ultra-high frequency (UHF) technology for recognizing and acquiring information via radio

frequency identification (RFID) is already widespread in logistics applications. There is still a lot of potential for other fields,

though: It is now finding its way into the industrial production. moreMap on a Chip
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5/9

For years, the Siemens Gertewerk Amberg manufacturing facility has relied on radio-

frequency identification (RFID) in its manufacture of electrical devices. Now RFID also controls the material flow in a newmanufacturing facility. moreCustomized Items off-the-Rack

The manufacture of as many identical pieces as possible is considered the key to an

economical series production, because identical production orders lower costs through economies of scale. But fewer and

fewer customers are satisfied with off -the-rack offers: They demand products adapted specifically to their needs. moreFast baggage identification with RFID

Every airline passenger expects his checked baggage to arrive at the destination airport with

him. This forces airports, especially those with high manual re-handling costs due to not readable barcode baggage tags, to

switch to new technologies. moreNew Momentum in the Electrical and Electronics Industry with RFID

While part one of the article (see ident 4/08) covered the new possibilities of the RFID

technology for the production and material flow control, the second part now concentrates on the benefits of the

contactlessly functioning RFID systems in the UHF range for the business-to-business logistics supply chains and for the

asset management of the intralogistics. moreTimetable in the Chip

Producing numerous product variants economically is a great challenge to every productionplanner. The Siemens works in Amberg has relied on Radio Frequency Identification (RFID) for many years to produce

different types in different batch sizes. In the latest plant, the material flow is now also controlled innovatively by

RFID. moreNew Momentum in the Electrical and Electronics Industry with RFID
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6/9

Whether the flexible production down to the smallest batch sizes, the traceability of the

products, or the transparency across the supply chain the demands made on the globally competing manufacturers in theelectrical and electronics industry are high. moreSafe Pack

Authorities are placing increasingly strict demands on the safety of pharmaceutical products. This also includes full

manufacturing documentation in which all packaging elements are identified automatically and the packaging process is

documented in detail. moreEven stronger together

Manufacturing Execution Systems (MES) are implemented close to production and deliver IT

functions for planning, control and analysis of production procedures. It is precisely in applications such as AssetManagement, Tracking and Tracing or Genealogy Management that MES systems display their strengths. The integration of

RFID into MES systems achieves further significant increases in productivity. moreQuickly Identified

Whether simple or demanding the Simatic RF300 RFID system reliably controls the production and material flow for all

identification tasks in industrial production. moreSafe Pack

Authorities are placing increasingly strict demands on the safety of pharmaceutical products. This also includes full

manufacturing documentation in which all packaging elements are identified automatically and the packaging process is

documented in detail. moreThe Senses of Automation

Hans-Georg Kumpfmller, Head of Sensors and Communications at Siemens, on the future

areas of application for sensors and the potential of RFID. moreThe Baggage Makes The Connection

Passengers expect to be able to retrieve their baggage on time at their destination. Because of

this, airports and airlines have to work extra hard to meet these expectations. Radio Frequency Identification (RFID) is an

important tool for this purpose. moreA strong combinationThe combination MES (Manufacturing Execution Systems) and radio frequency identification (RFID) allows greater

transparency and efficiency without the need for manual activities. moreRFID and the Search comes to an End
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