Shidian RFID Active Electronic Tag Facilitates Process Management Solutions for Production and Processing Enterprises

I. Project Background and Objectives

1.1 Project Background

In the daily operations of large-scale manufacturing and processing enterprises, process management, as the core of the production chain, directly impacts product quality, production efficiency, and cost control. Currently, most enterprises still rely on manual recording, paper document circulation, or traditional fixed clock-in devices for process management, which presents numerous pain points: manual records are prone to errors and omissions, making data accuracy difficult to guarantee; fixed clock-in devices are constrained by power sources and location, unable to adapt to the mobile operation scenarios of large equipment; process progress feedback is delayed, making it difficult for managers to grasp the real-time status of product flow through various processes; process data is fragmented, hindering the formation of a complete traceability chain and leading to inefficient溯源 when quality issues arise.
Addressing these industry pain points, our company introduces a process management solution based on dual-frequency activation technology. Leveraging the synergy between dual-frequency activation base stations and dual-frequency tags, combined with intelligent management software, this solution automates, refines, and visualizes process management during the production of large equipment, effectively overcoming the bottlenecks of traditional management models.

1.2 Project Objectives

• Precise Positioning and Automatic Clock-in: Achieve automatic positioning and clock-in of large equipment at various process nodes, replacing manual operations, and enhancing the accuracy and timeliness of process records.
• Real-time Visual Monitoring: Display the real-time location distribution of products (large equipment) across various processes through management software, enabling managers to intuitively grasp production progress.
• Data-driven Traceability and Analysis: Automatically collect data such as entry time, dwell duration, and exit time of equipment at each process, generating standardized reports to provide data support for production optimization and quality traceability.
• Flexible Adaptation to Production Scenarios: Utilize solar-powered mobile base stations to eliminate reliance on fixed power outlets, adapting to complex factory layouts and the mobile operation requirements of large equipment.

II. Introduction to Core Product Components

The core competitiveness of this solution stems from the integrated architecture of "Dual-frequency Activation Base Station + Dual-frequency Tags + Intelligent Management Software," where each component's functions complement each other to build an efficient process management system.

2.1 Dual-frequency Activation Base Station

As the core data collection terminal of the solution, the base station plays a key role in tag activation, location identification, and data upload, possessing the following core characteristics:

• Dual-frequency Communication Technology: Employs dual-frequency communication, balancing signal coverage range and positioning accuracy, enabling precise identification of activation signals from nearby process tags to ensure the accuracy of clock-in data.
• Solar + Backup Battery Power Supply: Supports solar power and is equipped with a high-capacity backup battery, allowing continuous operation for over 72 hours in environments without sunlight, completely eliminating dependence on fixed power sources, and enabling flexible relocation based on production needs.
• Rugged Industrial Design: Features an IP67-rated waterproof and dustproof enclosure, suitable for complex factory environments with dust, humidity, etc., and withstands a wide temperature range of -20°C to 60°C, ensuring stable equipment operation.
• Rapid Deployment and Adaptation: Supports various installation methods including ceiling mount, wall mount, and bracket mount; the installation process is simple, allowing quick adaptation to different workshop layouts; features automatic networking, enabling real-time data upload upon connection to the factory LAN.

2.2 Dual-frequency Process Tags

As the identification carriers for process nodes, the tags are affixed to key locations of each process (e.g., operation stations, inspection points, assembly stations), possessing the following characteristics:

• Dual-frequency Activation Response: When a dual-frequency activation base station approaches, the tag quickly responds to the activation signal, triggering location information reporting, with a response time ≤ 0.5 seconds, ensuring real-time clock-in.
• Long-lasting and Durable Design: Utilizes a passive design, requiring no charging, with a service life of up to 5 years; the housing is made of wear-resistant and waterproof material, resistant to mechanical impact and oil contamination in workshop environments.
• Unique Identification Code: Each tag is equipped with a unique ID code. Once bound with process information, it can accurately identify each process node, preventing confusion.
• Easy Installation: Supports various installation methods including adhesive backing and screw fixation, allowing quick attachment to surfaces of various materials like metal, concrete, and plastic at process locations.

2.3 Intelligent Management Software

As the data analysis and visualization platform of the solution, accessible via computer and mobile terminals, it possesses the following core functions:

• Real-time Map Monitoring: Import factory floor plans and intuitively mark the real-time locations of process nodes (tag locations) and large equipment (bound base stations) on the map; location information updates dynamically as equipment moves.
• Process Clock-in Records: Automatically record the entry time, exit time, and dwell duration of equipment at each process, generating clock-in logs searchable by equipment ID, process name, time range, etc.
• Data Report Statistics: Automatically generate multi-dimensional reports, including production duration statistics per process, equipment flow efficiency analysis, process bottleneck identification, etc.; reports support Excel export and printing.
• Traceability and Alerting: Trace the complete process flow trajectory of equipment via its ID; automatically trigger audible and visual alerts when equipment dwell time in a process exceeds a preset threshold (e.g., overtime without completion), prompting managerial intervention.
• Permission Management: Supports multi-level permission settings, assigning different operation rights to roles such as managers, workshop supervisors, and operators, ensuring data security.

III. Implementation Process

3.1 Preliminary Research and Planning

• Requirement Analysis: Communicate with relevant enterprise personnel to clarify the production process flow (e.g., raw material processing, assembly, inspection, packaging), the number and location of process nodes, the quantity and models of large equipment, and core management requirements (e.g., key monitoring of specific processes, traceability accuracy requirements).
• Site Survey: Conduct on-site inspection of the factory workshop layout, record spatial dimensions, obstructions, lighting conditions (informing base station placement), and identify potential sources of signal interference (e.g., large metal equipment, high-frequency motors).
• Solution Detailing: Based on survey results, determine the quantity and placement of base stations (ensuring signal coverage for all process nodes), tag placement locations and numbering rules, software report customization needs, etc., forming a detailed implementation plan.

3.2 Hardware Deployment and Installation

• Tag Installation: Affix dual-frequency tags at designated process node locations according to the plan, ensuring they are flat and secure. Simultaneously, input tag IDs and corresponding process names, locations, etc., into the management software to complete the binding.
• Base Station Deployment: Install dual-frequency activation base stations based on workshop layout and signal coverage requirements. For fixed process areas, use ceiling or wall mounting; for mobile large equipment, fix the base station on the top or side (ensuring no signal obstruction) and complete the binding between the base station and equipment ID. After installation, debug the solar power system and network connection to ensure normal data upload.
• Signal Testing: Activate base stations and tags to test signal strength and clock-in response speed at each process node. For areas with weak signals, adjust base station positions or increase their quantity to ensure full-scenario coverage.

3.3 Software Deployment and Debugging

• System Deployment: Deploy the intelligent management software to the enterprise server or cloud platform, complete database setup and network configuration, ensuring normal data communication between the software and base stations.
• Map and Data Configuration: Import factory floor plans, mark the locations of process tags and base stations in the software, input basic data such as equipment information and process flow, and set personalized parameters like alert thresholds and report templates.
• Function Debugging: Simulate the flow of large equipment through various processes to test the accuracy of software functions like real-time positioning, clock-in recording, report generation, and alerting. Optimize the software interface and functional logic based on enterprise feedback.

3.4 Personnel Training and Trial Run

• Operation Training: Conduct training for enterprise managers and workshop operators, covering daily maintenance of base stations and tags (e.g., cleaning solar panels), software operation (e.g., querying clock-in records, exporting reports), and troubleshooting common issues (e.g., signal interruption).
• Trial Run: Arrange a 1-2 week trial period, with technical personnel on-site for support. Collect user feedback to optimize base station locations, software parameters, etc., ensuring stable operation of the solution.

3.5 Formal Handover and Operation & Maintenance

Upon completion of the trial run, compile implementation documents (including installation drawings, operation manuals, parameter configuration sheets, etc.) and formally hand over the solution to the enterprise. Provide long-term operation and maintenance services, including equipment fault repair, software upgrades, data backup, etc., to ensure the solution continues to deliver value.

IV. Core Advantages of the Solution

4.1 High Flexibility, Adapting to Complex Production Scenarios

The base stations utilize solar power and support flexible mobility, allowing installation positions to be adjusted according to production plans. This perfectly adapts to the mobile operation needs of large equipment and workshop layout changes. Compared to traditional fixed-power devices, deployment efficiency is increased by over 60%.

4.2 High Precision and Reliability, Ensuring Data Quality

Dual-frequency communication technology ensures the accuracy of tag activation and location reporting, with a clock-in error ≤ 1 meter and a data upload success rate ≥ 99.5%. Industrial-grade hardware design suits harsh factory environments, with an annual equipment failure rate below 3%, significantly higher than the industry average.

4.3 End-to-End Digitalization, Enhancing Management Efficiency

Replaces manual recording and paper-based flow, automating process clock-in and data statistics. Managers can grasp production progress in real-time via the software, increasing traceability efficiency by over 80%. Automated report generation provides data support for production optimization, helping enterprises reduce process management costs by 15%-20%.

4.4 Easy Integration and Scalability, Protecting Enterprise Investment

The management software supports integration with existing enterprise systems like ERP and MES for data interoperability. The solution allows for the expansion of base stations and tags, enabling enterprises to add equipment as production scales up, avoiding repeated investment.

V. Safeguard Measures

5.1 Technical Support

Establish a dedicated technical team to provide full-process technical support from solution design and on-site implementation to后期运维; implement a technology R&D iteration mechanism to provide regular software upgrades and optimize functional experience based on industry technological advancements and enterprise needs.

5.2 Service Assurance

Provide a 7×24 after-sales service hotline; respond within 2 hours and arrive on-site within 48 hours upon receiving a fault report (excluding remote areas); offer 2 free on-site inspection services annually to comprehensively maintain base stations, tags, and other equipment, ensuring system stability.

5.3 Data Security Assurance

The software employs data encryption for transmission and storage to prevent data leakage; establishes a data backup mechanism with daily automatic backups, enabling quick recovery in case of data loss; implements permission management and operation log recording, ensuring full traceability of data operations.

VI. Conclusion

Leveraging dual-frequency activation technology, solar power technology, and intelligent management systems, this solution constructs an efficient, flexible, and precise process management system. It effectively addresses the issues of manual dependency, data latency, and traceability difficulties in the process management of large-scale manufacturing and processing enterprises. Through the implementation of this solution, enterprises can achieve digital control over production processes, enhance production efficiency and product quality, reduce management costs, and strengthen their core competitiveness.

Shidian Technology will utilize its professional expertise and services to tailor implementation plans for enterprises, assisting them in achieving intelligent upgrades in process management and jointly creating a new landscape of efficient production.