Intelligent factories generally use RFID technology to manage moulds, the core lies in its solution to the traditional mould management in the ‘out of control’ problem, at the same time for the intelligent manufacturing to provide key data support. The following are specific reasons for the analysis:
Crack the traditional management of the ‘four big problems’
- High dependence on manpower: traditional ledger or barcode easily due to human error caused by data errors, and RFID tags can automatically collect data to reduce human intervention.
- Non-transparent status: The number of times the mould is used, maintenance records and other information lags behind, RFID real-time writing data to ensure that the status of ‘what you see is what you get’.
- Efficiency bottleneck: barcodes need to be scanned one by one and are easily defaced, RFID supports batch reading (hundreds of tags can be identified per second), increasing efficiency by 5-10 مرات.
- Waste of resources: Unknown location of moulds leads to repeated purchases, RFID positioning function can reduce the redundancy of idle moulds by more than 20%.
Adapt to the injection moulding scene ‘hardcore ability’
- Resistant to harsh environments: علامات RFID are resistant to high temperatures (up to 300℃+), زيت, and metal interference, which is perfectly suited to the high-pressure, high-temperature scenarios of injection moulding workshops.
- Dynamic data storage: The tag can store mould specifications, maintenance records and even process parameters, making it a ‘talking mould’.
- Seamless Integration: It can be linked with MES and ERP systems, automatically triggering work orders, updating inventory, and synchronising ‘data flow – material flow’.
‘Data gold mine’ to drive intelligent decision-making
- Full Life Cycle Management: From storage, استخدام, maintenance to scrapping, RFID records every link of data, forming a ‘digital history’ of the mould.
- Predictive Maintenance: By analysing data such as number of uses, pressure and temperature, AI models can provide early warning of mould wear and reduce the risk of downtime.
- Capacity optimisation: Identify high-frequency moulds and target capacity expansion, or eliminate inefficient moulds, increasing resource utilisation by 15%-30%.
Case evidence: ROI significant cost reduction and efficiency gains
- An auto parts factory: After the implementation of RFID, the mould search time is shortened from 2 ساعات إلى 10 دقيقة, and the annual downtime loss is reduced by 2 مليون يوان.
- A home appliance company: through RFID to monitor the life of the mould, to avoid overloading the use of a single set of moulds to form the number of products increased by 18%.
- 3C industry benchmark: RFID data linkage digital twin system, the number of trial moulds to reduce the number of times by 40%, new product launch cycle shortened by 25%.
Future expansion: RFID is the ‘nerve endings’ of the smart factory
- Digital twin foundation: RFID real-time data-driven virtual mould model, simulation process optimization scheme.
- Supply Chain Collaboration: RFID-identified mould data connects customer-factory-supplier, enabling on-demand maintenance and rapid response.
- Carbon Neutral: Accurate management reduces mould scrap rate, reduces resource waste and carbon emission.
موجز: RFID is the ‘intelligent standard’ of mould management
In the smart factory, RFID is not only a technical tool, but also the core of the closed loop of ‘perception-analysis-decision-optimisation’. It will mould from the ‘black box assets’ into ‘transparent resources’, directly support the improvement of production efficiency, product quality and supply chain flexibility. With the deepening of Industry 4.0, the application of RFID in mould management will become a ‘must’ for the digital transformation of the manufacturing industry.
