Manufacturing is a complex business, primarily because it requires state-of-the-art machinery to produce equally complex and high-quality products. From a small plastic item to creating an automotive part made of metal, to running an assembly line where various parts are used to assemble a single finished good, it requires precision and quality control at each and every step.
Today, we are particularly talking about molds. Molds and dies are used in manufacturing to cast small or large parts or to make a finished good. Plastic molds, such as injection molds, blow molds, compression molds, and extrusion molds, which form plastic parts, are used by several manufacturing hubs that create furniture, home appliances, electronics, sports, and other items. Metal molds, like die-casting and forging molds, are used for metal products, automotive, jewelry, machinery, etc., and others, like glass, ceramic, foaming, and punching molds, are used in their respective industries.
Now, with a technology like Radio Frequency Identification (RFID), it is easier for manufacturing hubs to keep track of each mold, small or big, with a unique identification, using RFID tags.
RFID impacts how molds can be tracked, controlled, and reported upon in a timely way. With UHF metal-mount tags that are durable, embedded hard tags, NFC options, and RFID labels, RFID helps in managing molds, tracking, maintaining, and allocating molds accurately. RFID increases mold availability time, mold lifecycle, and decreases mold misuse or downtime potential and costs.
In this blog post, we will discuss RFID in industrial mold management, including the different kinds of RFID tags for industrial molds available in the market, and we’ll explain the benefits of RFID for cost-effective, ergonomically smart, and error-proof manufacturing using molds.
How Does RFID in Industrial Mold Management Work?
RFID tags are engineered to endure extreme industrial conditions directly on or in molds. These tags store unique identifiers and mold-related information. RFID readers, fixed or handheld RFID readers at various locations, including warehouses, operating floors, or maintenance areas, automatically capture various data related to these RFID-tagged molds. The information is then sent in real-time to management programs (usually an MES) to be included in real-time inventory, mold status, usage history, and location. This process eliminates the necessity for manual checking or recording information.
If a mold were to move from storage to the production line, the RFID tag would automatically be read and logged as molds were being transported to the production line. If the operator ordered the wrong molds to be installed on the machine, the system would alert them to the mistake, and they could make certain that the right molds are used on the right product every time.
Here’s a quick summary:
1.RFID tags: All mold-specific information (ID, specs, usages, maintenance) is coded into the tag.
2. UHF Band Tags: These tags offer longer read ranges and are built to operate on metal surfaces and at high temperatures.
3. RFID Readers: These readers will gather real‐time data about molds used during the production and warehousing sequence.
4. RFID Labels: Potential to be used as labels for easy visual identification and integration.
Types of RFID Tags Used for Industrial Molds
1. Metal-mount UHF tags- They are extremely temperature-resistant, anti-metal design, used for injection and die-casting molds.
2. Embedded hard tags- Chemicals, shocks, and pressure resistance. They are used for managing industrial assets.
3. RFID labels/stickers - They are inexpensive and work in lower-frequency environments. Ideally used for mold warehouse and maintenance.
4. NFC-enabled tags- Small RFID tags offering short read range and cost-effective identification and tracking of molds. These smart NFC labels can be scanned using an NFC-enabled smartphone as well.
Additionally, UHF (Ultra-High Frequency) tags are extremely popular due to their longer read ranges (up to 10 meters on metal) and their capability to survive extreme environments.
These labels can cost around INR4-5 per label.
Some Mount on-metal labels, designed for metal items, are slightly costlier, ranging between INR 35 and INR 40. Similarly, RFID hard tags are also costly, somewhere around INR 30-INR 100.
Benefits of RFID Technology in Industrial Mold Management
1.Mold Tracking: RFID no longer forces people to track molds manually and shows movements of molds through every status of the life cycle: warehouse, work-in-progress, and repair. Every mold will have its own unique and identifiable digital footprint, and can be traced back with a captive audit trail for compliance. It improves visibility of molds on the floor and reduces the chances of a mold being misplaced or stolen.
2. Mold Misuse Prevention: RFID makes sure that only the right molds are being used for the right jobs and will significantly cut down on errors and products rejected (in one auto parts manufacturer, defects dropped from 1.2% to 0.15%).
3. Mold Warehouse Operations: RFID/RTLS (Real-Time Location Systems) will automatically track molds and eliminate inventory variances and losses due to time spent in locating molds for dispatch to a production facility.
4. Production Cost Savings: The time spent managing molds to become ready for production is reduced, delays in mold management are reduced, RFID can become a new resource for productivity, duplicate purchases of molds are eliminated, and the manager should see an increase in mold productivity.
Important Benefits of RFID in Managing Molds
1.Live location of mold: Enables easy location and retrieval of mold quickly.
2. Automated Maintenance Notification: Improved tracking of molds. Prevent under- or overuse of mold, which can prolong their life cycle.
3. Minimised Errors: Minimises human touch points, reduces human errors, and reduces record-keeping entries.
4. Integrations: RFID integrates with MES/ERP and asset management. This improves and assists in planning, decision-making, and sourcing.
5. Upsizing and Retrofitting with Current Systems: Current RFID devices and systems can retrofit present molds and systems without modifying machine controls.
Things to Keep in Mind While Implementing RFID in Mold Tracking and Management
1.Mold RFID tags should be rugged (metal-mount, high temp)
2. You will maximise your ROI when you integrate your RFID into your current warehouse and production space.
3. Your RFID hardware needs to be reviewed and calibrated regularly so it operates optimally over time.
4. Make sure you think of data privacy and security (unique ID, nothing can be sensitive on the tag).
5. When you conduct a cost-benefit analysis, while the initial cost may seem daunting and difficult to allocate, it will be bigger than downtime, errors, and holding costs associated with inventory; it is more than manageable.
In conclusion, adopting RFID technology in the management of industrial molds can support rapid, automated processes, rather than cumbersome, manual (or even worse, paper) tracking of all forms of molds. RFID allows for greater efficiencies, longer service lives for mold, fewer errors, and improved overall asset control, making RFID technology an essential part of smart manufacturing.
Frequently Asked Questions
Q1. What is RFID, and how is it relevant in mold management?
RFID (Radio Frequency Identification) is a wireless technology that identifies and tracks objects with RFID tags. RFID applies to mold management for tracking, maintenance, and control of the mold assets during their lifetime, from manufacturing to the end of the product life cycle.
Q2. What RFID tags are suitable for use in industrial molds?
Rugged UHF metal-mount tags are the best solution, since they will not be impacted by the heat, pressure, or chemicals used in the molding process.
Q3. Will any RFID integration efforts force us to replace our existing molds or machines?
No. Although some RFID solutions could present additional considerations, most RFID solutions can easily be added to existing molds. Most RFID solutions integrate very easily, if not seamlessly, into current warehouse and asset management systems, with very little or no impact.
Q4. What tangible benefits can a manufacturer expect from using RFID?
Expect faster inventory management processing times, faster downtime and maintenance times, fewer lost or mismanaged molds, and the ability to leverage data to enhance processes.
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