World Electric RFID Active Electronic Tags Assist Production and Processing Enterprises in Process Management Solutions

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 limited by power sources and fixed locations, unable to adapt to mobile operation scenarios of large equipment; process progress feedback is delayed, making it difficult for managers to grasp the real-time flow status of products across processes in real-time; process data is fragmented, making it challenging to form a complete traceability chain, leading to inefficient root cause analysis when quality issues arise.
To address the aforementioned 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 to enhance the accuracy and timeliness of process records.
• Real-time Visual Monitoring: Display the real-time location distribution of products (large equipment) across processes via management software, allowing 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 dependency on fixed power outlets, adapting to complex factory layouts and the mobile operation needs of large equipment.

II. Introduction to Core Product Components

The core competitiveness of this solution stems from the trinity architecture of "Dual-frequency Activation Base Station + Dual-frequency Tags + Intelligent Management Software." Each component complements the others' functions, collectively building an efficient process management system.

2.1 Dual-frequency Activation Base Station

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

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

2.2 Dual-frequency Process Tags

As the identification carriers for process nodes, tags are affixed to key locations of each process (e.g., operation stations, inspection points, assembly workstations), featuring 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. Response time is ≤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 impacts and oil contamination in workshop environments.
• Unique Identification Code: Each tag is equipped with a unique ID code. Once bound to process information, it can precisely identify each process node, avoiding confusion.
• Easy Installation: Supports various installation methods including adhesive backing and screw fixation, allowing quick attachment to surfaces of various materials such as 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 devices, it features the following core functions:

• Real-time Map Monitoring: Import factory floor plans and intuitively mark the real-time locations of each process node (tag location) and large equipment (bound base station) on the map. Location information updates dynamically as equipment moves.
• Process Clock-in Records: Automatically records the entry time, exit time, and dwell duration of equipment at each process, generating clock-in logs. Supports querying by equipment number, process name, time range, etc.
• Data Report Statistics: Automatically generates multi-dimensional reports, including production duration statistics per process, equipment flow efficiency analysis, process bottleneck identification, etc. Reports support export to Excel and printing.
• Traceability and Alerts: Trace the complete process flow trajectory of equipment via its number. When equipment dwells at a process exceeding a preset threshold (e.g., overtime for processing), the system automatically triggers audible/visual alerts to prompt manager intervention.
• Permission Management: Supports multi-level permission settings, assigning different operation permissions to roles such as managers, workshop supervisors, and operators to ensure 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 each process node, the quantity and models of large equipment, and core management needs (e.g., key monitoring of specific processes, traceability accuracy requirements).
• Site Survey: Conduct on-site inspection of factory workshop layout, recording spatial dimensions, obstructions, lighting conditions (to inform base station placement) at each process location, and identifying potential signal interference sources (e.g., large metal equipment, high-frequency motors).
• Solution Refinement: Based on research results, determine the number and placement of base stations (ensuring full signal coverage of 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 to each process node according to the planned locations, ensuring they are flat and secure. Simultaneously, enter tag IDs and corresponding process names, locations, etc., into the management software to complete binding.
• Base Station Deployment: Install dual-frequency activation base stations based on workshop layout and signal coverage needs. For fixed process areas, use ceiling or wall mounting. For mobile large equipment, fix the base station on top of or to the side of the equipment (ensuring no signal obstruction) and complete the binding between the base station and equipment number. 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 number 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 to ensure 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, enter 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 alerts. Optimize the software interface and functional logic based on enterprise needs.

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 run period, with technical personnel on-site for support. Collect user feedback to optimize base station placement, software parameters, etc., ensuring stable operation of the solution.

3.5 Formal Handover and Operation & Maintenance

After the trial run, compile implementation documentation (including installation drawings, operation manuals, parameter configuration tables, 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

Base stations utilize solar power and support flexible relocation, allowing adjustment of installation positions based on 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 improved by over 60%.

4.2 High Precision and High Reliability, Ensuring Data Quality

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

4.3 Full-process 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 software, improving traceability efficiency by over 80%. Automatic generation of data reports provides 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 supports scaling the number of base stations and tags, allowing equipment additions as production scale expands, avoiding redundant investment.

V. Safeguard Measures

5.1 Technical Support

Establish a professional technical team to provide full-process technical support from solution design and on-site implementation to后期运维. Establish a technology R&D iteration mechanism to provide regular software upgrade services based on industry technological developments and enterprise needs, optimizing functional experience.

5.2 Service Support

Provide a 7×24-hour after-sales service hotline. Upon receiving a fault report, respond within 2 hours and arrive on-site within 48 hours (excluding remote areas). Provide 2 free on-site inspection services annually for comprehensive maintenance of base stations, tags, and other equipment to ensure stable system operation.

5.3 Data Security Assurance

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

VI. Conclusion

This solution, leveraging dual-frequency activation technology, solar power technology, and intelligent management systems, constructs an efficient, flexible, and precise process management solution. It effectively addresses issues in process management for large-scale manufacturing and processing enterprises, such as reliance on manual labor, data delays, and traceability difficulties. Through the implementation of this solution, enterprises can achieve digital control of production processes, enhance production efficiency and product quality, reduce management costs, and strengthen core competitiveness.

Shidian Technology will provide professional technology 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.