gp report on rfid

RFID FOR SHOP FLOOR MANAGEMENT

A dissertation submitted in partial Fulfillment of the requirement for the

award of Degree in

Bachelor of Fashion Technology (Apparel Production)

Submitted By

SHREYA AGARWAL

Under the Guidance of

MR. DEEPAK KUMAR

Department of Fashion Technology National Institute of Fashion Technology, (Hyderabad)

May,2014

CERTIFICATE

“This is to certify that this Project Report titled “RFID for shop floor management” is based on

my SHREYA AGARWAL original research work, conducted under the guidance of

MS.SHARMILA SURE towards partial fulfillment of the requirement for award of the

Bachelor’s Degree in Fashion Technology (Apparel Production), of the National Institute of

Fashion Technology, HYDERABAD

No part of this work has been copied from any other source. Material, wherever borrowed has

been duly acknowledged.”

Signature of Author/Researchers

Signature of guide

ACKNOWLEDGEMENT

It is a well-established fact that behind every successful work there is hand of numerous people. I

take this opportunity to acknowledge their help and express my gratitude towards them.

I would like to thank Shahi Exports Pvt Ltd. for giving me an opportunity to learn industry skills

through this project and to explore my potential and develop a professional attitude.

I would like to express my deep sense of gratitude and heartfelt thanks to my industry mentor,

Mr. Deepak Kumar (Sr. I.E. Executive) for his constant aid and support and guidance

throughout the span of this project which helped me in accomplishing this project. He showed

interest in my ideas and helped me proceed with them.

I would thank Mr. Deepak Rautela (Head of Organizational development and training dept.) for

carrying my project further towards implementation.

I would like to express my sincere thanks to Dr.N.J.Rajaram (Director –NIFT Hyderabad), Mr.

Shakeel Iqbal (Centre Co-coordinator DFT) and college mentor, Ms. Sharmila Sure for her deep

interest and motivation delivered to me that made this work possible. Her continued guidance

and motivation gave this project its final shape.

Last but not the least I would like to thank Mr. Gunish Jain (An expert in RFID implementation

for garment industries, )Orient fashions, Pempro, Sahu Exports for being extremely cooperative

and sparing their valuable time for my research work.

1. INTRODUCTION

In today’s challenging business environment, manufacturers face greater mandates for speed,

efficiency, quality, and process visibility. Industrial manufacturing continues to evolve,

constantly adapting to meet the ever-increasing productivity and efficiency demands on the

factory floor.

RFID (Radio frequency identification) is one of the greatest virtues that can help streamline

operations, increase worker productivity, and control costs.

Radio-frequency identification (RFID) is a technology that uses communication via radio waves

to exchange data between a reader and an electronic tag attached to an object, for the purpose of

identification and tracking. Some tags can be read from several meters away and beyond the line

of sight of the reader. The application of bulk reading enables an almost parallel reading of tags.

It collects and analyzes production data during the entire production workflow on a real time

basis. This specifically deals with common production problems encountered on the shop floor.

An RFID system not only obtains information about production quantities in real time basis but

also traces the efficiency of each line, traces the performance of each sewing machine and each

worker. Most importantly it detects the source of the problem in real time. It shows who is

working in which bundle, fast resolution of bottlenecks and rapid tracing of quality issues to their

source.

1.1 PROJECT BRIEF

This project focuses on the proper management of the backbone of a garment industry i.e. the

sewing shop floor. It presents how the non-value adding activities can be removed and the

management of the sewing shop floor becomes systematized using Radio Frequency

Identification.

1.2 PROJECT LOCALE

Shahi Exports pvt ltd.

Industrial plot no. 1

Sector 28, Faridabad

Haryana

1.3 TITLE OF THE PROJECT

RFID for shop floor management

1.4 OBJECTIVES OF THE PROJECT

Improve Visibility and Flexibility

Improve Global Competitiveness

Make Better Informed & More Timely Decisions

Balance Production & Improve Delivery Times

Improve Product Quality & Reduce Chargebacks

Improve Employee Morale & Reduce Turnover

Significantly Reduce Actual "Labor Cost per Unit"

1.3. NEED OF THE PROJECT:

Radio frequency identification for shop floor management was needed in order to avoid all the

non-value adding activities on the shop floor. These activities include manual preparation of:

Manpower report (Floor wise and line wise)

Daily Production report (Floor wise and line wise)

Hourly production report

Item wise SAM report

Time study reports

Also, efficiency calculation at the operator level was not possible. Hence, no incentive program

could be effectively implemented thus leading to less motivation among workers to improve

their efficiencies.

1.5 BENEFITS OF RFID

Increase operator productivity

Decrease excess labor costs

Reduce payroll overpayment

Reduced W-I-P and throughput time

Eliminate the cost of gummed sheets and counting

Reduce the cost of gross payroll calculations and producing the net payroll

Reduce job/bundle handling costs

Eliminate lost time at time-clocks

Fast resolution of bottlenecks

Rapid tracing of quality issues to their source

In order to frame this project in the best possible way and reach to the finest solution for the shop

floor management, several research papers and articles were reviewed. These are briefly

discussed in the next section.

2. LITERATURE REVIEW

The success and growth of an apparel manufacturing business depends on how well cross-

department production information is delivered, handled and executed in real time. What is

required is a reliable platform to fulfill all these aspects of business.

Radio frequency identification (RFID) technology is the call of the hour to improve the

operational flow in such a complex environment of apparel production business. It collects and

analyzes production data during the entire production workflow on a real time basis. This

specifically deals with common production problems encountered on the shop floor.

Talking about production, an RFID system not only obtains information about production

quantities in real time basis but also traces the efficiency of each line, traces the performance of

each sewing machine and each worker. Most importantly it detects the source of the problem in

real time. It shows who is working in which bundle, fast resolution of bottlenecks and rapid

tracing of quality issues to their source.

RFID technology is becoming a popular tool for factory management in the apparel industry.

Although this service is offered by many solution providers in various areas, the functions of

those systems are quite similar to each other. Main components of the system are RFID software,

computer, data cable, RFID card, RFID scanner, RFID reader and terminal to display

information to the operator.

2.1 RFIVD vs. BAR CODE SYSTEM

Attribute RFID Bar code

Transmission Electromagnetic/ wireless Optical

Reading capability Non-line of sight Line of sight

Tag reading Multiple One by one

Reading speed 500/min 80/min

Moving object reading Yes No

Data modification Read/Write Read only

Data volume 1 kb <100 bytes

Both system have their own advantages and disadvantages. In the following I have compared

both systems in different parameters.

2.1.1 Process flow: Main differences in data capturing to report generation are.

Bar code: Print Bar codes --> Bundling with Bar codes --> Stick Bar codes on

gum sheet by operators --> Scan Bar codes by scanner --> Report generated

RFID system: Writing on tags --> Bundling with tags --> Bundle tag scanning by

operators --> Report generated

2.1.2 Scanning Speed: Multiple RFID tags can be scanned at a time and RFID reader

scan tags from any direction within a limited distance. Only one bar code sticker can be

scanned at a time and Bar code scanner scan a Bar code from front only. So RFID system

is faster in data capturing.

2.1.3 Installation and running Cost: For Bar code initial cost is less compared to RFID

but running cost will be high in case of Bar code system. RFID can be reused many times

where Bar codes consumed once can’t be re-used.

2.1.4 MIS and Reporting: In RFID you will get real time information. Real time

information can be displayed on terminals (operator console) in front of operators which

is the most important part of shop floor controlling. Where in case of Bar code you will

get updated information once someone scan bar codes. Normally after each two hours

production data is scanned in bar code system.

Reporting formats depend on Bar code / RFID suppliers how they designed their

package. Similar report can be produced from both Systems. In RFID system you will get

update within a fraction of seconds.

2.1.5 Manpower requirement: In Bar code system factory need to employ a scanning

person. On the other hand sewing operators scan tags on their own at the time they start

bundle.

2.1.6 Carbon Footprint: This point is also important because at present apparel industry

is concerned on reducing carbon footprint. In bar code system you will consume lot of

gum sheet and sticker which increases your factory carbon footprint. In RFID based

system no use of any paper. Data is sent to the main server via wires.

2.2 TYPES OF RFID TAGS

In real time RFID system, data is captured through scanning of RFID cards (tags) at operator

terminals (workstation). Generally, four types of tags are used in the line which can be an

employee card, bundle card, supervisor card or a job card.

2.2.1 Employee card: Employee cards are issued to operators and checkers. Operator

uses employee card to sign on at his/her workstation. If operator does not scan the

employee card system keeps her absent for the day. One more important thing, without

scanning the employee card operator would not be able to scan bundle cards at his/her

terminal.

2.2.2 Bundle card: Bundle cards carry a unique number (bundle no.) that is made in

computer to represent the bundles such as garment size, no. of pieces consist in bundle

etc. Bundle cards are attached to each bundle as similar to bundle tickets. When operators

work on the bundle they scan bundle card to the terminal. One or multiple cards are

issued against each bundle depending on the production system. For example, when

garment is made on sections (preparatory sections) and assembled at the end for each

sub-bundles duplicate cards are issued. In some RFID systems, bundle card is inserted to

the slot of the terminal while operator sews garment instead of scanning.

2.2.3 Job card: Job cards used to assign jobs at the terminals (workstation). Job cards are

also used for special purposes. Normally, each terminal (work stations) is pre-set with the

operation/job that would be performed by the operator. There may be possibility that

operator had to do multiple jobs. In that situation, operators use job card to change the

operation in the terminal. Jobs cards are labeled with job (operation) name and number.

Operator scans the job card of the job that will be performed by the operator.

2.2.4 Supervisor card or maintenance card: This system has option to record off-

standard work and lost time. To authenticate those lost time approval by supervisors or

assigned person is needed. Also when machine breakdown is reported by operator and the

issue is solved by the maintenance, they scan their card to stop the lost time request.

2.3 WORKING OF AN RFID SYSTEM

The process flow of the system has been explained in the following.

2.3.1 Data preparation: Data preparation consists of task such as listing of operations

for the style Assigning of SAM for each operation. Listing of employees, supervisors

Listing of machine type and class. Create bundles for each cut (lay).

2.3.2 Assigning job/operation to the terminal: In the line, each operator would perform

specific job. Prior to start work on the workstation operation is assigned to the terminal

(workstation). Assigning of job can be done by using job cards or entering job number to

the terminal.

2.3.3 Issuing card: According to the bundling done by the cutting department, RFID

cards are scanned by RFID scanner to assign bundle number to the cards. Assigned cards

are issued to the cutting department. These cards refer to the bundle numbers created on

the computer. Bundle numbers includes information such as quantity of garment, size,

color etc. Bundle cards are then attached to the bundles.

2.3.4 Scanning of cards at terminals: Each operator scans bundle cards (at RFID reader

that fixed on their work station) and start working on bundles. When operator finishes the

bundle, he/she ties the RFID card with bundle and keeps aside or moves to the next

operator. Once operator scans the card, information related to that particular bundle will

be stored and displayed to the computer.

2.3.5 Viewing report: System records all transactions made by operators and

supervisors. System analyses the records and display reports on the pre-set format.

Modification of digital information can be possible by administrator. For example,

system gives report of individual operator’s efficiency. Now how system calculates

efficiency? To calculate someone’s efficiency system needs two types of information –

how many minutes operator has produced during the day and secondly how many

minutes operator spent or present (sign in) at his work. First information is calculated

through total bundle scanned (total pieces) and multiplying the pieces by SAM of each

pieces (for the operation). Second information is captured from employee card scanning

data – at what time they sign in at the terminal and at what time they sign off from the

terminal.

RFID system captures all the information through RFID scanners and stores them in the

database. Whatever report one needs can be displayed retrieving data from the data source.

2.4 The RFID-based Garment Manufacturing Information System

The major components of the RFID-based garment manufacturing information system include:

RFID Token, which is a low frequency (13.56 MHz) and passive tag. Its unique ID is

associated with the bundle of cut-raw materials (such as sleeves, cuffs and hoods) which

are to be used to fulfill each order.

RFID Readers, which are installed in the cutting department, next to each sewing

machine and QC tables.

PC workstation, which connects 40 sets of RFID readers in business structure. Data were

collected to a PC workstation before uploading to the computer server.

Ethernet system which is used to transmit data from PC station to server.

2.5 Working

Workers’ attendance cards: When a worker goes to work, he/she will scan the RFID (Worker ID

Card) instead of the attendance card. Then, the computer system will record the total working

time and transfer the data to the company’s wages and accounting systems. This way, the payroll

department will be able to calculate his/her wages and finish the relevant human-resources

management works in a shorter time. Upon requests from the clients compliance (code of

conduct), workers’ RFID cards are also used by the factory for worker identification, work

records, salary calculation, etc., giving extra edge to the factory.

Typically, the management does find it difficult to monitor and understand the factory’s

production flows by using the traditional paper-based ticket records. The workers will

accumulate the records until just before the pay day (or will they use those records for

manipulating their overtime works). This will present extra difficulty for the factory in

calculating the salaries payment and related costs, hence further confusing the production

progress.

RFID Production Cards are registered through the readers at every machine or production

equipment, so that the information for the start and end of each job can be transmitted to the

main server for storage and processing. The application will calculate automatically and perform

statistical analysis on the production progress and unit salary costs, further achieving “Real-Time

Production Management Flow” and carrying out a complete monitoring processing in the shop

floor. The system is designed to show alert on the line balancing of each production department

as well as provide a large amount of data on staff production value and equipment utilization rate

for analysis.

To obtain information / data and trace it more accurately and real time: By employing wireless

technologies, RFID technology manages to transform the traditional paper-based information

system in the production line into a fully-computerized system for data storing and processing.

Industry can benefit less administrative costs and faster processes and feedback. Meanwhile,

RFID and ERP systems are collectively used for management-control in areas of material

control, monitoring the production WIP progress, order tracing, storage, logistics, recording sales

data and related security to improve the entire efficiency of the business process. It is the world

trend that the RFID technology is becoming more popular to replace the bar codes at a low cost.

RFID technology, for better flow amongst the sewing machines in the WIP process.

2.6 Some common on-site difficulties and problems faced by garment

factories:

Production workers at garment factories usually have a habit of keeping their job ticket.

This not only increases the factories’ overtime expenses due to compliance requirement

of extra compensation but also prohibits the factories from accurately estimating its

workers’ productivity.

Low efficiency in production is mainly due to a lack of sense of quantification in the

management’s mind. It may also be the consequence of a lack of planning in production,

a low utilization rate of equipment as well as a poor coordination of production

departments.

Loss of control in monitoring. For example, when there is bottleneck in certain

production steps in the line, the system fails to issue a warning within a short period of

time. In most factories, there are no measuring tools or standards which actually display

the workers’ performance. This finally causes serious production jam.

There is no database built up for in-depth analysis. In reality, a lot of factories already

have various types of computerized technology networks in place for monitoring their

production. These computerized processes and models do support a lot of different

settings. This will only significantly increase the factories’ maintenance costs.

Furthermore, the factories will also find it very difficult in obtaining the necessary data

for enterprise planning (some real-time statistical data regarding the production).

3. METHODOLOGY

3.1 Theoretical construction of the thesis

Initially literature review was done, so as to gain basic knowledge about the project before going

to the workplace. It is of utmost importance to have the theoretical knowledge and collection of

some sort of secondary data about the project, so that when it mingles up with the practical

knowledge in real time after going to workplace, it directs and molds the path in which the

project would be accomplished effectively.

3.2 Defining objectives

Defining the objectives clearly helped to focus on the goal of the project and provided a path

for the research.

3.3 Preparation of questionnaires for survey

Reviews on the project topic were taken from the concerned authorities and the concerns

were duly noted. Thus, the requirements of the project were framed.

3.4 Data collection and analysis

Working area was analyzed thoroughly, and the whole production flow was tracked. This gave

the basic idea about the various problems prevailing in the workplace. Problem identification

gives us the idea about the areas where the improvement could be done so as to arrive at the

positive results.

3.5 Field visits

Field visits to various industries were made in order to have a practical and real time idea of

the system. These visit were meant to analyze the pros and cons of RFID implementation for

the garment manufacturing.

3.6 Problem findings and their solutions

The identified problems were studied in depth so as to find their root cause. This usually take

some sort of time but it is very much needed so that prevailing problems could be rectified and

positive results would be derived based on the comparison made between the conditions before

the implementation of the project and after the implementation of the project.

3.7 System implementation

A prototype is supposed to be made and implemented in small section, so as to have the real

time working feasibility and thus to get the positive results. This will include the training of the

operators of that particular section and instructions are drawn to help the operators to follow them

so as to make the project work effectively and efficiently giving us the positive results.

3.8 System testing and further improvements

After the implementation of the idea in small section, the whole implementation process and its

outcome is analyzed so that if there are any sorts of flaws prevailing in the system, could be

rectified. These flaws need to be analyzed in depth as the next step is to implement the idea in the

whole workplace. So, it will be easy for a person to rectify these flaws while idea is being

implemented in small section rather in whole workplace.

4. VENDOR SELECTION

Four vendors were shortlisted as per our requirements of the project for the management of shop

floor.

These were:

Tagsys rfid

GPRO technologies

Tag n track solutions

Leadtec cgs inc.

The vendor selection was carried out on the basis of various criteria such as

implementation cost, maintenance cost, returns on investment, quality, customer reviews,

post-sale service etc.

The comparison sheets are shown below:

5. Cost analysis

Based on the vendor selection, a detailed cost analysis was done for Leadtec cgs inc solution

providers. Based on real time data and calculations, returns on investment was calculated.

FOR 30 SEWING LINES

Contribution per garment 100

Monthly Factory Cost of Operator 9,360

Cost Per Operator Per Day 360

Current Production per Operator 10

Productivity Improvement 20%

No. of Extra Garments Made Per Operator Per Day 2.00

Extra Contribution per operator per day 200

*Reduction in Cost of a Garment 6

Cost Saving Per Operator Per Day 72

Total Extra Contribution Per Operator Per Day 272

Total Contribution Per Month 7,072

Operator Utilization During the Year 50%

Annual Contribution Per Operator 42,432.00

No. of Operators 1,200

Total Contribution For the year 5,09,18,400.00

Cost of Terminals 2,74,50,000

Payback Period 6.47 Months

ROI 185%

Price of Terminal is $220/Terminal + $95/Terminal for license i.e $315/terminal

Software license fee - $8,000 - server license

Terminal License - $95/Terminal.

$8000 = Rs. 4,88,000

$315/terminal = Rs. 19,200 (approx)

For 44 terminals = Rs. 8,45,460

For 85 terminals = Rs. 16,33,275

4,88,000 + 8,45,460 = Rs. 13,33,460

4,88,000 + 16,33,275 = Rs. 21,21,275

FOR 2 SEWING LINES












Total Contribution Per year 84864



No. of Operators 85

Total Contribution For the year 36,06,720

Cost of Terminals 21,21,275

Payback Period 7 Months

ROI 185%

FOR 1 SEWING LINE












Total Contribution Per year 84864



No. of Operators 44

Total Contribution For the year 18,67,008

Cost of Terminals 13,33,460

Payback Period 8.5 Months

ROI 170%

6. SAMPLE DEMONSTRATION

Demonstration

The following is a quick go-thru of the actual application of the technology.

Operator Status shows current day efficiency and operator wise output

Section efficiency gives the line wise efficiency

Approve Off Std – To check operator off standard time & approve it

Line Balancing helps in better utilization of operator

Loss Time Report

Poor

Lin

e B

ala

ncin

g

Wash R

oom

No C

uttin

g

New

Sty

le S

ettin

g

Makin

g S

am

ple

Machin

e B

reak D

ow

n

Meeting

Wait F

or

Thre

ads

Wait F

or

Needle

Poor

Qualit

y S

td.

47.8%

86.3%

93.2%

98.4% 99.4%

100.0% 100.0% 100.0% 100.0% 100.0%

0%

20%

40%

60%

80%

100%

0

5

10

15

20

25

30

35

40

45

50

Cum

ula

tive %

Hrs

.

Causes

[Loss Time Analysis]

Vital Few Useful Many Labels Cumulative% [42]

Cumulative Percentage Cutoff: 80%

# CATEGORIES LOSS TIME(HRS.) Cumulative%

1 Poor Line Balancing 46.48

47.8%

2 Wash Room 37.47

86.3%

3 No Cutting 6.71

93.2%

4 New Style Setting 5.042

98.4%

5 Making Sample 0.94

99.4%

6 Machine Break Down 0.6

100.0%

7 Meeting 0

100.0%

8 Wait For Threads 0

100.0%

9 Wait For Needle 0

100.0%

10 Poor Quality Std. 0

100.0%

Cumulative Percentage Cutoff: 80%

# CATEGORIES LOSS TIME(HRS.) Cumulative%

1 Wash Room 68.92

85.3%

2 Poor Line Balancing 7.91

95.1%

3 Machine Break Down 2.74

98.4%

4 Meeting 0.41

98.9%

5 Making Sample 0.35

99.4%

6 Wait For Needle 0.33

99.8%

7 New Style Setting 0.17

100.0%

8 Wait For Threads 0

100.0%

9 No Cutting 0

100.0%

10 Poor Quality Std. 0

100.0%

Wash R

oom

Poor

Lin

e B

ala

ncin

g

Machin

e B

reak D

ow

n

Meeting

Makin

g S

am

ple

Wait F

or

Needle

New

Sty

le S

ettin

g

Wait F

or

Thre

ads

No C

uttin

g

Poor

Qualit

y S

td.

85.3%

95.1% 98.4%

98.9% 99.4%

99.8% 100.0% 100.0% 100.0% 100.0%

0%

20%

40%

60%

80%

100%

0

10

20

30

40

50

60

70

80

Cum

ula

tive %

Hrs

.

Causes

[Loss Time Analysis]

Vital Few Useful Many Labels Cumulative% [42]

7. CONCLUSION

Practical exposure of any theoretical concept cements the knowledge level. The project which I

pursued in Shahi Exports pvt ltd. helped me a lot to know more about the area I studied in a

more practical way.

The project dealt with the use of radio frequency identification on the production shop floor.

Other than this, system provides real-time production data for closer monitor of production

defects, downtimes, efficiency, production line visibility and other issues such as process

reengineering. It builds a culture of open discussion and scientific management, which is linked

to the concept of continuous improvement.

It also improves the work motivation of staff by creating an image that the company is willing to

invest in helping the employees to enhance their work efficiency and obtain a higher payroll and

bonus.

Some more advancement could be done to the implemented system so as to get more real time

production vision

8. BIBLIOGRAPHY

REFERENCES (BOOK):

• Womack, J., Jones, D., & Roos, D. (1990). The machine that changed the world. New York:

Macmillan.

• Quick Overview of Process Mapping (Charles E. Wilson, TreQna University).

• The Toyota way (Jeffery K. Liker)

• Moore, Ron. 2002. Making Common Sense Common Practice: Models for Manufacturing

Excellence, (pp. 34-36, 48). Boston: Butterworth-Heinemann.

REFERENCES (WEBSITE)

• http://www.learnleanblog.com/2009/07/kanban-push-to-pull-processing.html

• http://www.slideshare.net/tanujkujur/kanbanultimate-adi-apparel-interns

• http://www.kanban.com/

• http://en.wikipedia.org/wiki/Kanban

• http://www.technicaljournalsonline.com/jers/pastissue/Article15JERSVolIIssueIJuly-

Sept.2010.pdf

gp report on rfid

Documents

rfid implementation

project report

successful work

work possible

guidance of ms

production data

continued guidance

shop floor management