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 Simatic S7

The Amberg site is considered the crown jewel of the Siemens group: For many years, over 1,000 employees have been making the numerous modules of the successful controller family Simatic S7. The main goal of the production engineers: The quality of the products. After all, the Simatic components are used worldwide by Siemens customers in countless factories for controlling production sequences device failures would result in a production stop and thus considerable costs. At the same time, the Amberg plant has to of course operate at maximum efficiency to remain competitive at the international level. This becomes all the more difficult as the Simatic family now offers a great variety of products for different applications. The task is: Organize the production sequences in such a way so that an economical 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 as mass-produced goods, rather each product is treated as a unique specimen, explains Bernhard Streber, responsible for identification technology at the electronics manufacturing plant. This is made possible by a flexible production concept, 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 packaging workstations, where for each individual product, the accessory items enclosed, e.g., cables, documentation, software CDs, are shown on the monitor and their removal from the storage bins is checked. Optical Codes as Key Technology To control this complex system, the identification of each product at every work step is necessary. For efficiency reasons, this can only take place automatically. In doing so, the electronics manufacturing plant primarily relies on optical codes. Encoded are the unique specimen number of each part, intermediate product, and final product. A powerful Oracle database then provides all information required to the individual workstations in real-time by means of a Web service. In addition to the actual production information, e.g., the parts list for a product, this data also includes extensive test specifications and reference values for the quality assurance. The codes are printed by inkjet onto adhesive labels, or lasered on directly. Even parts from suppliers receive a plant-internal unique specimen number at the incoming goods department, says Bernhard Streber. This is easier and more target-oriented than to agree 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 space requirement. For instance, it is possible to uniquely mark even the smallest of modules such as connectors or printed circuit boards. Another advantage: Since the 2D code is considerably smaller than a bar code, it can also be applied much faster by laser. As a result, we were able to lower the cycle time by 2.5 seconds per product, explains Streber the 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, the production time, the measurement results, and much more. These audit trails are of particular importance in safetycritical components to prove the error-free production in case of doubt. In addition, the data collection also helps in optimizing the quality, since certain error patterns can be detected at an early stage.

Optimization of the Read Results For reading in the codes, the electronics manufacturing plant mainly uses in-house camera systems: The Simatic VS130-2 is something like the workhorse in the plant. Thanks to the separate arrangement of sensor head and interpretation unit, the camera system can be installed even in the cramped machines close to the conveyor. The seamless integration into the Simatic controllers makes the engineering especially quick and easy. The most important 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 camera developers: We already tested the cameras prior to the product launch, and provided real code images for the system test, reports Streber. Altogether, the electronics manufacturing plant employs over 50 cameras of the model Simatic VS130-2 in the production. Next to optical codes, the identification by radio is also increasingly used in the Amberg electronics manufacturing plant. Radio Frequency Identification (RFID) is employed wherever specific circulating goods such as workpiece carriers or soldering frames need to be identified. The advantage: Since the data storage media (transponders) can be written to as often as desired, the radio chips can be reused almost an unlimited number of times. For instance, at the 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 the 2D 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 RF300 transponder. When inserted into the machine, the soldering frame and the hold-down fixture are indentified by a reader; a comparison with the production program immediately uncovers incorrectly positioned soldering frames or hold-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, are important elements for the comprehensive quality assurance of our products, says Bernhard Streber. RFID Use in the Supply Chain According to Streber, the potential for RFID applications in the plant has not been fully tapped yet. In particular the automation of the supply logistics presents a promising field of application. For instance, it is being considered to permanently mark the individual units manufactured with RFID to ensure a clear tracing also in the distribution logistics; a use that the colleagues of the Siemens telephone manufacturing plant in Leipzig, Germany, have already implemented. There, each device of the OpenStage line is now equipped with an RFID radio chip. The problem in Amberg: The Simatic components are constructed very compact resulting in different device component possibly shielding the RFID transponders. But the resourceful engineers of the Amberg plant will surely come up with another trick here to get a step closer to the vision of an automatic product identification for the entire lifecycle. Automatic Identification Whether 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 be employed for diverse tasks in the production and logistics. For both technologies, Siemens supplies a wide range of detection 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, and clear acquisition. It offers easy recognizability through its boundary patterns as well as security through special data encryption with data redundancy. As a result, even partially dirt-contaminated or damaged information can be reconstructed automatically. RFID, on the other hand, is based on radio waves and thus particularly insensitive to dirt contamination. The transponders provide a large storage capacity of up to 64 KB and can be written to virtually an unlimited number of times. Thus, extensive production and quality data can be stored directly at the product or workpiece carrier. Thanks to the long range when utilizing the UHF frequency band (865 MHz), logistics applications, too, increasingly attract notice. 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

opens up new application possibilities. more Series 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). more Auto 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 the 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. more The 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. more The 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. more Increased 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. more Synchronization 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. more Synchronous with reality

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. more Wireless 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. more Simple 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. more Transparency 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. more Reliably identified

Product identification was already utilized by stonemasons of the antiquity. In manufacturing plants, it increases their flexibility and economic efficiency. more UHF 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. more Map on a Chip

For years, the Siemens Gertewerk Amberg manufacturing facility has relied on radiofrequency identification (RFID) in its manufacture of electrical devices. Now RFID also controls the material flow in a new manufacturing facility. more Customized 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. more Fast 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. more New 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. more Timetable in the Chip

Producing numerous product variants economically is a great challenge to every production planner. 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. more New Momentum in the Electrical and Electronics Industry with RFID

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 the electrical and electronics industry are high. more Safe 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. more Even 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 Asset Management, 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. more Quickly Identified Whether simple or demanding the Simatic RF300 RFID system reliably controls the production and material flow for all identification tasks in industrial production. more Safe 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. more The 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. more The 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. more A strong combination The combination MES (Manufacturing Execution Systems) and radio frequency identification (RFID) allows greater transparency and efficiency without the need for manual activities. more RFID and the Search comes to an End

During the manufacture of products, add-on parts or semi-finished parts are transported from a processing station or production line to the next processing step. The documentation of the current status and the next step is customarily carried out using so-called routing slips, which are attached to the part or the transport device. more Properly detected

For intelligently controlling the flow of materials and the production, as in the just-in-sequence production and for the assured traceability of products or batches, machine-readable and automated, non-contact identification systems are increasingly being utilized. more Auto-ID The Key to efficient Automation

Whether in the tracking of products, the management of supply chains, or the traditional production control nothing works anymore without automatic identification. It aids in safely detecting and controlling the flow of goods and materials. Data Matrix code and RFID are the technologies for efficiently and reliably carrying out the automatic identification tasks. more Greater Productivity with RFID

When used in combination with RFID systems, Manufacturing Execution Systems can assume complete control of production, thereby optimizing processes, and thus increasing productivity. more RFID in Closed and Open Loops

RFID technology improves production and logistics processes in the industrial as well as the retail and wholesale sectors. Manufacturing operations mainly use closed-loop applications, whereas logistics firms largely rely on open-loop applications. more

Valtra has automated the material supply process and material buffer management with RFID at its Suolahti tractor manufacturing plant. The RFID system implemented by Vilant Systems triggers replenishment orders based on material consumption movements directly to the suppliers. Goods receiving is automated with RFID enabled conveyors and RFID gates at the dock doors and material stock levels are maintained in real time. The system improves material handling efficiency and reduces manual errors. The real time material inventory information and inbound shipment data enable prevention of material shortages.

Vatras system is based on RFID enabled forklifts that read material pallets while transporting them from the material buffer to the consumption area and trigger replenishment orders. The system is based on pallets that have reusable RFID tags. Goods receiving dock doors and inbound conveyors are equipped with RFID readers for automatic goods reception. Vilants RFID software controls the RFID readers and integrates the information to Valtras ERP system.

The Vilant Server 5 RFID software system presents real time inventory information of the material buffer. For each material a target buffer amount is set. For single materials the buffered quantity can be followed. The buffered amount, pending replenishment orders and inbound shipments are visible. The information is based on Valtras RFID readers and readers deployed to suppliers. The material flow visibility provided by the RFID system can improve material availability at the factory. Goods receiving automation saves labor cost in the inbound process. Real time visibility of goods movements enhances control and inventory information is more accurate. The real time replenishment for material consumption improve inventory cycle time. In total the RFID system improves many areas of material flow. Improving material flow is one of the key components of modern Lean production improvement methodology. Valtras Supply Chain Manager Timo Husso has expanded RFID development to new areas already: Thorough preparation work for this system implementation was started already in 2003. We conducted an RFID pilot that gave us satisfactory results and experience. New application areas emerged quickly, too. We have implemented production traceability and internal material movement automation with RFID already. Valtras RFID system is based on Vilant Server 5 RFID software and Vilants RFID hardware products. Prior to production use the system was piloted with Valtras supplier Metalpower.The IT systems were implemented in partnership with Tieto and Liaison.