RFID Tag Tracking for Container Misbuild Reduction
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Solution Overview
Problem
In powertrain manufacturing environments, quality campaigns are typically passive and manual, making it difficult to track and manage containers and products, especially in extreme conditions, leading to misbuilds and increased costs due to unreliable tracking methods and high attrition rates of metal racks.
Innovation Solution
An electronic method and system using extreme condition identification tags, such as RFID or barcode tags, to uniquely identify containers and products, allowing for reliable tracking and management, even in harsh environments, by associating product IDs with container IDs and using tracking devices to monitor locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual tracking methods are used in extreme manufacturing conditions, then operational simplicity is maintained, but tracking reliability deteriorates due to interference issues and high attrition rates of metal racks
Solution Approach 1:
The patent replaces manual tracking methods with an automated electronic tracking system using RFID tags and readers. The system automatically identifies and tracks containers and products through electronic signals, eliminating the need for manual intervention and significantly improving tracking reliability in extreme manufacturing conditions.
Solution Approach 2:
The patent introduces RFID tags as intermediary devices attached to containers and products. These tags serve as mediators between the tracking system and the objects being tracked, enabling reliable identification and location monitoring even in harsh environments with metal racks and extreme conditions.
2Productivity
If passive and manual quality campaigns are conducted, then system simplicity is maintained, but productivity deteriorates due to difficulty in tracking and managing containers and products
Solution Approach 1:
The patent replaces passive manual quality campaign execution with an active automated system that continuously monitors container and product locations using RFID technology. This automation enables real-time tracking and management, significantly improving productivity in quality campaigns.
Solution Approach 2:
The patent implements a feedback mechanism where RFID readers continuously scan and report the locations of tagged containers and products. This real-time feedback enables the system to automatically update tracking information and alert personnel to potential quality issues, improving overall quality campaign execution efficiency.
3Measurement precision
If visual inspection is used to verify product types in racks, then equipment simplicity is maintained, but measurement precision deteriorates making error proofing unreliable and not manually feasible
Solution Approach 1:
The patent replaces visual inspection with automated RFID identification systems. RFID readers electronically scan and identify products in racks, providing precise and accurate product type verification without human intervention. This eliminates the limitations of visual inspection and makes error proofing reliable and feasible.
4Productivity
If handheld scanners are used to track suspect engines or transmissions, then system simplicity is maintained, but productivity deteriorates making the process cost prohibitive and sometimes impractical
Solution Approach 1:
The patent replaces handheld scanner operations with fixed RFID readers positioned throughout the facility. These readers automatically detect and track tagged engines and transmissions as they move through the manufacturing process, dramatically increasing tracking speed and efficiency while reducing labor costs and improving practicality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables proactive and efficient tracking and management of containers and products, reducing misbuilds and costs by ensuring accurate identification and location tracking, thereby improving the execution of quality campaigns and reducing the number of good products flagged as suspects.
Implementation Method 1
placing an extreme condition identification (ID) tag encoded with a container ID on a location on a container capable of containing one or more products
Data Source
AI summary
An electronic method for monitoring the location of a container and one or more products capable of being contained in the container in an operating environment. The method can include the steps of (a) placing an extreme condition identification (ID) tag encoded with a container ID on a location on a container capable of containing one or more products; (b) associating the one or more products with the container ID; and (c) tracking the location of the containers based on the extreme condition ID tag.