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iWorkPMS - RFID Production Monitoring & Control

Posted Wed, 05/27/2009 - 18:26

Most garment manufacturers have no system in use or are currently using the traditional “paper ticket” method to manually record the work data which is time-consuming and inaccurate. Information cannot be shared, there are no measuring tools for workers’ performance and no database built up for in-depth analysis. This not only presents difficulties in calculating actual costs for each garment and increases expenses, but also prohibits the management from accurately estimating workers’ productivity and monitoring production progress.

A new technology used for identification, known world over as RFID (Radio Frequency Identification) employs radio wave to transmit information. RFID’s auto ID entry and re-writable characteristics make it viable and economical to apply in garment manufacturing.

iWorkPMS has adopted this cutting edge RFID technology to provide full visibility on production floor performance. The system utilizes low frequency RFID technology to capture real-time data during the entire production work flow, thus the transmission, tracing, storage and retrieval of information will become much smoother, and the whole process more transparent.


iWorkPMS Real Time Data Collection Flow

iWorkPMS enables whole Work in Progress monitoring, the data collection flow is not limited to the above processes, but any other processes which may be involved such as washing, quality control, pressing, folding, etc.


Functions and Features:

  • Real Time Data Capturing

    Unique RFID cards associated with electronic identity are embedded to production items throughout the manufacturing cycle. The RFID cards are registered through the reader at every workstation, so that the information for the start and end of each job can be transmitted to the main server at real-time for storage, categorizing, tracing, processing and analyzing.

  • Real Time Monitoring

    The system allows promptly update of production-line information, offers real-time visibility of the whole Work In Progress production. Real-time information can be shared securely and conveniently no matter where you are. Management and line managers can access to the real-time data at anywhere anytime, so as to monitor the progress of each task, understand employee’s individual working efficiency, and supervise production line performance.

  • Work Place Control

    The RFID device installed at each workstation provides full traceability, thus enables management to trace line issues, anticipate the time required for a specific task, and manage the production floor to ensure high performance.

    • Anticipates bottleneck before it occurs.
    • Identifies production downtime and the causes for non-productive time instantly.
    • Real-time understanding on the rework rate helps to identify sources of defects. Any problem happened can be solved quickly, results in better quality control.
    • Achieves production line balancing by proactively responding to real-time detection of bottlenecks and production downtime.
    • Improves production planning accuracy and performance by synchronizing workflow, coordinating the equipment and staff for better harmonization.
  • Load Balancing

    By tracking worker productivity, material usage, work in progress, etc., iWorkPMS helps in assigning balance operations between resources in order to get optimal machine and labour utilization, minimize response time, and improve production sequencing. The assignment is done such that overall production rates can be achieved with all stations operating at near maximum capacity.

  • Remote Monitoring

    It allows remote immediate visibility and monitoring to factory performance no matter where you are through the internet or over local area networks. Management can now check up on the working progress and efficiency at anytime, thus achieves better control on the production floor. iWorkPMS helps in making timely and accurate decisions, facilitates quick response to production situation and ensures high performance all the time.


Analysis and Reporting

iWorkPMS provides a large amount of data on staff production value and equipment utilization rate for analysis, enables the enterprise to manage resources effectively. The application will automatically calculate and perform statistical analysis, sophisticated management reports can be generated instantly:

  • Operational Efficiency Analysis

    In-depth analysis on working efficiency, production output, SAM (Standard Average Time) vs. actual data comparison, key performance indicators, learning curve by task by team, etc.

  • Worker’s NPT (Non-Productive Time) Analysis

    Understands the causes and duration for each production down time. Helps in improving production plans and scheduling operations.

  • Re-work Cause Analysis

    Provides analysis on the defect types and re-work duration. Helps to identify sources of defects, reduce reworks and improves quality.

  • Finished goods Reports

    Provides statistics on finished goods with detailed breakdown by colour, size, PO, etc., helps to understand the current status.