Production tracking & identification systems

1.1 IDENTIFICATION SYSTEMS

Identification is done to make an unknown entity known. A basic requirement for identification is that the ID is unique, and built from a collection of quantities that are unique. It is is the capability to find, retrieve, change, or delete specific data without confusion. This is very important for information in databases. (Cheema)

1.1.1 BARCODES

• A barcode is a machine readable code, with information coded on it.
• The information is coded on a visible surface which can be scanned.
• They are also sometimes called as UPC codes.
• Barcodes need to be in line of sight of the scanning device, and each barcode must be scanned individually.
• Once a barcode is printed, the data in it cannot be changed.
• Only 20 characters can be coded in a barcode.
• If one line is missing from the code or if the barcode is wrinkled, it will not get scanned

1.1.2 QR CODES

• QR codes need to be scanned individually with a scanner.
• The code cannot be changed once it is printed.
• One QR code can contain up to 7000 characters.
• Even if a QR code is wrinkled, all of the data is not lost as long as the outer box of the code is intact.
• They can be scanned by mobile scanners, and the data can be extracted to excel.
• Also, printing barcodes and QR tags or stickers are not really expensive, when compared to the benefits they can give if implemented successfully in a company.

1.1.3 RFID TAGS

• RFID tags are used for automated inventory management, and do not require to be scanned individually.
• They constantly send out a signal, and hence they are a good choice to use for up-to-the minute live product tracking.
• Products with RFID tags can be scanned in bulk, by being passed through an RFID scanner.
• The data of the tag can be changed and the tag can store thousands of characters.
• An RFID tag cannot be specific to a particular reader, so the information in it can be read by any reader, which makes it easy for someone else to get the data in the RFID.
• These tags operate on radio frequency, and can easily be jammed or disrupted, or experience signal issues which can lead to high time consumption and decrease in productivity.
• RFID implementation takes a lot of time to set-up, with high initial costs.

(How important is barcode for clothing and apparel)

(What is a QR-Code, 2016)

1.2 TRACKING SYSTEMS

For developing any tracking system, 4 main components are required:

• A traceable item
• A tracking method
• A baseline to compare the actual results
• A way to generate, and distribute the information

Using the above components, a method can be implemented along with a computerized system.

Figure 1: Proposed methodology (Cooray, 2015)

The first step is to determine a traceable item, after which a barcode should be generated and attached to it to trace it. Then, to track the item, there should be a tracking method set up in each processing step.

Conventionally, a barcode reading unit is plugged into a computer system, and the information is transferred from the reader to the computer. Android applications are also available which can be developed with a barcode reading function, and they consume lesser space and cost lesser money as compared to the conventional barcode reading system.

Once the system is set up, it is necessary to make sure that everything is going as per plan. For this, a planned set of operations is assigned at every point of the flow, along with the planned time with each operation uniquely identifiable. This is the baseline to compare the final results with.

Figure 2: Subsystems & main system (Cooray, 2015)

An analytical dashboard can be present at the last step to display, generate and distribute information and also provide real time information to support the decision making process.

The tracking system will consider many tracking sub-systems. Each sub-system will have a database which will be linked to the main sub-system. These sub-systems can be connected through intranet, or any Wi-Fi network (Cooray, 2015).

1.2.1 ADVANTAGES OF A TRACKING SYSTEM IN AN APPAREL FACTORY

The Identification System in apparels is used to identify various quantities at various stages to make them traceable at any later stage and keep a track of the work done and the work to be done. The logic involved in an identification system reduces human involvement and gives the entity of the product as well as the process, with a separate identification. This traceability logic can help the local apparel industry by increasing the quality and customer satisfaction. It can also help in reducing the faults and claims of by the customers due to such mistakes, and to keep a track of the worker’s performance and skill.

This logic includes the identification of every step involved in the value addition process in an y apparel organization. It also helps to track unexpected defects, their origin and the person responsible for it. It helps the organization to provide the customer with more safety and security regarding the product quality. Apart from the garment manufacturing industry, this logic can also be useful in the apparel shops and outlets as well.

The information of each unique ID has to be entered into these databases on daily basis, and can be done in two ways:

• Real time processing
• Batch processing

In real time processing, data updating is done simultaneously as the event happens. This is a good, effective method for tracking, but can be costly and difficult to implement.

Batch processing on the other hand, is a way to process data in “a batch” at any particular time after the event has occurred. (Cooray, 2015)

1.3 WAYS OF TRACKING WITH RFID

1.3.1 ABOUT RFID TRACKING

In the past 10 years, RFID has been penetrating in many companies to track goods, and to enhance inventory management. RFID stores EPC (Electronic Product Code), and is very different from barcode which can store only 13 digits. The EPC Code does not store any data, but the code is referenced to further data sets which contain the information (Al-Kassab, 2010).

The three main components of RFID are:

• RFID tag (transponder)
• RFID reader (transceiver)
• Software (for data processing)

The RFID reader scans the RFID tags which contain information in a digital form. A collection of wireless and wired networks facilitate the communication of the information from the tag to the RFID reader, which then broadcasts a radio signal through an antenna to the tag. Information of the tag can be read from the chip of the tag, once it responds to the radio wave. The reader then decodes the signal provided by the tags and transmits to the CPU. Then, the software receives and interprets the information collected from the tags and stores it. (Nayak, 2015).

1.3.2 RFID

2.3.2.1 Implementation example:

RFID is apparent in the retail industry as it can also be customized to provide valuable insight on customer behaviour. An RFID implementation was done by Galeria Kaufhof, and after the implementation results it was found that RFID helped her to identify the following:

• Inefficient promotion execution (i.e. articles that were put too early on the front store)
• Stock-out and overstock (when articles are out of store or exceed a certain amount)
• Storage inefficiencies (i.e., when the number of articles in the back store exceeds the number of articles on the front store – replenishment problems)

The following were the problems faced by her while implementing the system:

• The read rate was not always 100% accurate.
• All items had to be equipped with transponders to get detected.
• The paper mentions how RFID data is not very useful since it requires further extraction and filtering.
• RFIDs have more value if they are linked to some operational systems to link product information and codes.
• Privacy is an issue, as an RFID tag can be scanned by any scanner since RFID scanners are not specific (Khan, July 2016).

Many publications talk about the benefits of RFID in supply chain management, and that they benefit the supply chain by improving the efficiency, accuracy and the security of material and information flows. However, not many publications assessed the benefitted business value due to RFID. (Al-Kassab, 2010).

1.3.3 QR-CODES vs. RFID

(itemit.com, 2018), (Sarkar, 2012).

1.3.4 REAL TIME TRACKING

One more solution is by using something like an iWorkPMS System, which utilizes low RFID technology to get data real time production data which makes the whole process more smooth and transparent (Khan, July 2016).

1.4 EXAMPLES OF SYSTEMS IN THE MARKET

1.4.1 PRO-RFID – METHOD’S CONSULTANCY

Radio Frequency Identification is an automatic identification technology that is used to describe a system that transmits the identity (in the form of a unique serial number) to an object wirelessly, using radio waves. Unlike bar-code technology, RFID technology does not require contact or line of sight for communication.

A basic RFID system consists of three components:

• An antenna
• A transceiver (with decoder)
• A transponder (RF tag) electronically programmed with unique information

1.4.1.1 HOW COMPONENTS WORK?

• The antennas emit radio signals, thereby activating the tag and then read the data on to it.
• The reader emits radio waves in ranges of anywhere from 1 inch to 100 feet or more. Depending on its power output and the radio frequency used when the RFID tag passes through the electromagnet zone, the reader’s activation signal is detected.
• The data which is encoded in the tags integrated circuit (silicone chip), is decoded by the reader and is then passed to the host computer for processing.

The company had developed a complete RFID solution to enhance the information flow. On time accurate information was hence possible at a touch of a button from fabric receipt to dispatch monitoring the cutting room, the sewing and finishing departments, quality sections, WIP control, and line balancing. It was used as an operations management tool.

1.4.1.2 IN THE CUTTING SECTION

The entire Lay information i.e. lay no., size, color, number of plies and optimum bundle quantity was entered into the system to generate a bundle list. Tags were also initialized for each bundle / garment to be produced and were attached to each bundle / garment.

1.4.1.3 IN THE SEWING SECTION

Right before the start of every new style, each terminal needs to be assigned with specific operations based on the sequence. As all the bundles / garments progress the tag is passed over the terminal and the information on the tag is read into the computer, the information is processed instantly and a host of production orientated data is generated.

1.4.1.4 FOR LINE BALANCING AND WIP CONTROL

As production lines run, constant re-balancing is essential to maximize output. Since WIP information is live, all variations to the planned WIP are immediately viewable, supervisors and management can see the operations out of balance and work to rectify them. The software has a positioned screen on every line which shows WIP levels on every operation. The optimum level is shown in green and variations are shown in different colors indicating high or low WIP. Thus, bottle neck management becomes a simple process.

Information on the terminal

The RFID terminal has the following information available:

• Start time
• Efficiency
• Off standard time
• Quality
• Bonus earnings
• Garments produced
• Outstanding repairs and other information as required Following reports or queries are immediately available:
• Efficiency reports — Individual/Line/Department/Factory
• Lost time control — All sections
• WIP tracking — all orders
• Running Line balance position — WIP levels on all operations
• Bundle tracking — late bundles, problem bundles
• Piece work earnings per person
• Line profit or loss — live per line or subsection
• Attendance
• Quality info — per operator, style, problem operations, per line, per factory
• Bottlenecks
• Skills matrix — Automatically updated
• Incentive earnings

(Methods Apparel)

1.4.2 EXAMPLE OF IDENTIFICATION SYSTEM IN A GARMENT FACTORY

• In a garment manufacturing unit, bundles of work are identified using tickets. Self-adhesive operation stubs represent each operation the bundle moves through. The operator responsible for a particular operation removes the appropriate stub once he has completed

the bundle and this is stuck on to his daily work sheet. This system also records any ‘off standard’ time that an operator may experience during the day.

• At the end of the day the daily work sheet will have recorded on it all work carried out by an operator during that day, together with details of any down time. The work sheets for all the operators are then collected at the end of each shift and given to the IT Department for subsequent data and information processing.
• The use of ‘real time’ in production control is accurate up to the last bundle processed by any operator, and can be used in this example. Instead of stubs being removed from the ticket and stuck on to a work sheet, information can be read by computer immediately the bundle is completed at each workstation. In this case, a terminal is required at each workstation. These terminals are nothing but an input device, which are normally small numeric keypads on which the operator can enter the output or any appropriate information.
• Hence the concept of real time requires more employees, more technology and more working space which adds to the cost of the production and is not used in the local apparel industry (Cheema)

REFERENCES

• Al-Kassab, J. (2010, July). RFID in the Apparel Retail Industry. Retrieved from file:///C:/Users/lenovo/Downloads/13_RFIDintheApparelRetailIndustryACaseStudyFr omGaleriaKaufhof.pdf
• Cheema, M. F. (n.d.). Product Identification & Traceability in Apparel.
• Cooray. (2015). A Real Time production tracking system.
• How important is barcode for clothing and apparel. (n.d.). Retrieved from

Wondersoft: https://www.wondersoft.in/blog/important-barcode-clothing-apparel- pos/

• itemit.com. (2018, 11 06). QR vs. RFID, which is better? Retrieved 1 2020, from itemit.com: https://itemit.com/qr-vs-rfid-which-is-

better/#:~:text=QR%20codes%20must%20always%20be,radio%20frequency%20that ‘s%20being%20used.&text=So%2C%20not%20only%20are%20RFID,also%20have%20 many%20more%20applications.

• Methods Apparel. (n.d.). Pro-RFID Methods Apparel. Retrieved 01 13, 2020, from

Methods Apparel: http://methodsapparel.com/pro-rfid.aspx

• Nayak. (2015). RFID in textile and clothing. Springer Open (Fashion & Textiles), 16.
• What is a QR-Code. (2016). Retrieved 2020, from QR Code.com:

https://www.qrcode.com/en/about/

An Article by:-

1. Akshaya Ganesh
2. Vanshika Thakur