Smart Assembly Line Of Material Handling

Grade: 051011/051010

Report of Industrial Engineering

Our main objective is to transfer materials from warehouse to assembly line by the help of advanced technology like RFID.

Problems faced during traditional materials transportation ‣The supervisor can not clearly know the status and workload of the operators;‣The supervisor just made a plan, but during the materials transportation stage, the real-time data can not be automatically feed back;‣When production exceptions occurs (e.g. lack of materials, scrap products), the materials system can not rapidly response. ‣The supervisor is not able to instruct and give advice on how to handle hazardous materials that may be harmful for the operators health without proper safety equipment.

Distribution and control of all processes would be by one single person, which would be the supervisor.

User friendly way for supervisor to control and solve problems during the transformation of materials in this way the supervisor would avoid any Irregularity and disturbance of material mismanagement.

If a problem arises the supervisor would send an instruction to solve and handle at once to the operators.

What is RFID?

Radio-frequency identification (RFID) is the wireless use of radio-frequency electromagnetic fields to transfer data. Its main purposes is to automatically identify and track tags attached to objects.

‣ Real-time notification of security when RFID tagged items leave area without scanning.

‣ Real-time notification of out-of –stock items

‣ Improvement of product replenishment

‣ Know how many units of inventory or on-site via automated RFID system versus manual process, saving labor and time cost.

Reduce production time and employees.Improve material control. Improve efficiency and reduce the cost.Improve the rapid response capability.

Supervisor

Operators

The above figure shows the relationship between an operator and manager and how they both are interlinked with the help of the RFID device.

Assembly Line (A-2)Assembly Line (A-1)

X

Y

Road

Road

W1-1

Road

W2-1 W3-1 W4-1

Machine Machine Machine Machine

DatabaseMove Task ProgressOperator LocationsMaterials Status

Warehouse Assembly line

Work Flow LogicWork Flow Logic

MoveTaskID

Location1(Warehouse

MaterialPick up)

Location2(Assembly Line

Material Drop off)

MaterialID

QuantityOf

Material

OperatorID

1 W1-1 A-1 M1 2 Chang913

2 W2-1 A-1 M4 3 Yang901

3 W4-1 A-1 M2 1 Chan971

Move Task Progress

Operator Locations

RFIDTag locationID X Y Operator taskstatus

0012323 W1-1 x1 y1 pending

0012324 W2-1 x2 y4 done

0012322 W4-1 x4 y2 In progress

Materials Status

RFIDTag MaterialID Current Location

In stock

0012323 M1 In warehouse Y

0012321 M3 In trolley N

0012322 M4 In assembly line

Y

PROBLEMSAND

SOULTIONS

Problem description; The supervisor cant not know whether the operator has finished or not finished a task and that

operator is working or not.

Problem Solution; By the help of the RFID device the supervisor gets to know the exact status and workload the

operator is facing. By this way the supervisor would know the exact location of the operator and that whether the operator is active or not.

Problem And Solution1.The supervisor can not clearly know the status and workload of the operators;

Problem description;The supervisor just made a plan, but during the materials transportation stage, the real-time data can not be automatically feed back to the supervisor.

Problem Solution;By the use of advanced technology such as RFID the supervisor would have real time feed back of the material transportation stage.

Problem description;When production exceptions occurs (e.g. lack of materials, scrap products), the materials system can not rapidly respond.

Problem Solution;As supervisor would know the exact status of the different materials available at the different locations so he would easily know when the materials need to be replenished

MaterialsNeedTo be

replenished

Problem description;The supervisor is not able to instruct and give advice on how to handle hazardous materials that may be harmful for the operators health even with proper safety equipment.

Problem Solution;By using advanced technology the supervisor would be able to instruct real time on how to handle hazardous materials and this way the operator would be able to execute these processes.