La introducción de RFID (Identificación por radio frecuencia) technology in industrial mold management can bring multi-dimensional core value to the manufacturing industry with its advantages of non-contact data collection, high reliability and automated management.
1.Improve production efficiency, reduce downtime loss
Accurate positioning in seconds, eliminating the time-consuming process of ‘finding the mould’
By implanting high-temperature, Anti-metal Etiquetas RFID (such as UHF band tags) for moulds, combined with fixed readers deployed in workshops and warehouses, the system can locate the position of moulds in real time (with an accuracy of ±0.5 m). Data from an auto parts factory shows that the average time to find a mould has been reduced from 20-30 minutes of manual searching to less than 30 segundos, which directly reduces the downtime of the equipment waiting for moulds, and increases the annual production capacity of a single production line by about 15%.
2.Eliminate moulds misuse and ensure product quality
Unique electronic identity to prevent the risk of ‘wrong mould’
The RFID tag of each mould stores the unique ID and process matching information (por ejemplo. applicable models, processing materials, precision level). When the mould is mis-installed into the mismatched equipment, the system immediately triggers an audible and visual alarm, avoiding batch rejects due to moulds that do not match the product specifications. After the application of an electronic factory, the defective rate caused by the misuse of moulds has been reduced from 1.2% Para 0.15%, and the annual quality loss has been reduced by more than 2 millones de yuanes.
Full-process data traceability, rapid location of quality problems
Each time the mould is used, the processing batch, the cumulative number of stamping/injection times and other data are uploaded to the MES system in real time, forming a ‘mould – producto – defect’ correlation file.
3.Fine operation and maintenance management to prolong mould life
Predictive maintenance to avoid sudden failure
Based on the data collected by RFID, such as the frequency of mould use and load duration, combined with AI algorithms to establish a life prediction model, it warns of potential risks such as mould fatigue and cracks 3-5 days in advance. Through this mechanism, a home appliance manufacturer has reduced the number of sudden mould failure downtime by 60%, and increased the compliance rate of maintenance plan from 70% Para 95%.
Standardised maintenance records to optimise maintenance strategies
Maintenance personnel use handheld terminals to scan mould labels and automatically retrieve historical maintenance records (por ejemplo, last
time of mould change, model of replacement parts) to ensure that maintenance is carried out according to standard procedures (por ejemplo, rails must be lubricated every 500 uses). Data show that the average life of the mould has been extended from 8,000 times of traditional management to 12,000 veces, and the life cycle cost of a single mould has been reduced by 30%.
4.Intelligent inventory management, reduce warehousing costs
Batch inventory and dynamic monitoring, inventory accuracy rate of 99.9
Through the deployment of door readers at the entrance and exit of the warehouse, it can read 500+ mould labels within 30 meters at one time, achieving the efficiency of inventorying 2000 pieces of moulds per minute, que es 50 times higher than the efficiency of manual inventorying. After the application in a mould leasing enterprise, the inventory discrepancy rate was reduced from 5% Para 0.05%, and the capital occupied by backlog moulds was reduced by 40%.
Intelligent inventory preparation and automatic warning
The system automatically calculates the safety stock based on the frequency of mould usage and production scheduling, and automatically triggers the procurement application when the stock of a certain type of mould is lower than the threshold value. Combined with supplier collaboration, ‘zero inventory’ management is achieved, and the utilisation rate of storage space is increased by 60%.
5.Digitalisation of the whole life cycle to support decision-making and optimisation
Data-driven mould asset control
From mould procurement (entering initial parameters), producción (binding equipment), mantenimiento (recording spare parts replacement) to scrapping (automatically triggering asset write-off), the whole process data is synchronised in real time in the PLM/MES system, forming a complete digital twin file. Managers can visually view KPIs such as integrated mould utilisation (OEE) and single-mould output contribution through Kanban, providing an accurate basis for capacity planning and equipment investment.
Compliance and anti-counterfeiting management
For high-end precision moulds (por ejemplo. automotive cover part moulds), RFID tags can be written with encrypted anti-counterfeiting information to prevent unauthorized copying or use, especially suitable for scenarios with high demand for intellectual property protection.
6.Adapt to harsh industrial environments, stable and reliable operation
RFID tags using epoxy resin encapsulation or metal anti-jamming design, can be in – 40 ℃ ~ 200 ℃ high temperature, dusty, strong electromagnetic interference environment, stable work (such as die-casting workshop, heat treatment furnace next to the), the level of impact resistance up to IP68, life expectancy of more than 10 años, far better than the traditional barcode (easy to wear and tear, stained and fail). After a heavy industry enterprise deployed in the open mould yard, the label recognition rate maintained over 99.8% for a long period of time, which completely solved the problems of paper labels failing in rainy days and 2D codes being unable to be recognised due to wear and tear.
