Controls Carrier Boxes within Processes
Problem: The components, dies, etc., that are needed for the processing and assembly lines of home appliances are conveyed in carrier boxes or totes. A paper list is placed in the boxes, and the parts are sorted while checking the list at each process. This system is inefficient and lends itself to human error. Many companies would like to improve on it without having to make a large investment. Bar code labels are attached to carrier boxes, and a bar code reader is used to read the labels at each sorting stage. However, when labels become soiled, they cannot be read or they cause reading errors. Or, to lessen the parts control burden on the host computer, companies have switched to a system that issues parts-distinguishing labels for each component instead of carrier box-distinguishing labels, but the cost of issuing the labels and the extra work of replacing them is driving up operating costs. Companies are therefore seeking to improve on this system. Mount Data Carriers (ID Tags) onto the carrier boxes carrying the components. Use a special holder that allows the Data Carrier to be easily mounted and removed for this. Write bit data to the Carrier Data for distinguishing components (for example, 00000000 for component A, 00000001 for component B, 00000010 for component C, and 00000011 for component D; up to 258 components can be distinguished with eight bits). Install a system with Intelligent Flags and a PLC at each process to automatically read the component bits and sort the components accordingly.