Note: Descriptions are shown in the official language in which they were submitted.
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MANAGING PRODUCTION AND
OPERATIONS USING READ/WRITE RFID TAGS
BACKGROUND OF THE INVENTION
1. Field of the Invention
This inveiition relates generally to the field of managing production and
operations,
and in particular, to a method for establishing and recording a history of a
process from
manufacture to final sale or other use.
2. Description of Related Art
One of the problems reported in Production and Operations Processes Operation
Management is inaccurate data acquisition, both in Manufacturing Processes
(MRP systems)
and in Operation processes, for example, warehouse management, shipping,
distribution, and
inventory control and article surveillance at the point of sale.
Another problem is that in traditional Production and Operations processes
there is no
recorded history of the process or processes concerning a product. The lack of
recorded
history is due to the absence of communication links or networks between the
processes
themselves and between the processes and the products that are processed.
In a standard Production and Operations Processes Operation, as illustrated in
Figure
6, communication between processes is not possible all the time for a number
of reasons. The
processes can be distant form one another, for example being implemented in
different plants
and even different countries. The processes can also be fundamentally
different from one
another, for example, foundry operation, machining and distribution.
As a consequence, there is no information on the conditions of the processes
linked
to the product. The information of the conditions can be expressed in terms of
efficiency of
the processes, duration of the processes and incidents that affect the
products. As a more
basic consideration, the conditions can also be a determination as to whether
a particular
process has even been performed or implemented in the first instance.
A standard production and operations processing sequence 10 is shown in Figure
7.
A product is shown in four stages denoted by 12A, 12B, 12C and 12D. In
processing station
14, the product in stage 12A can, for example, be subjected to one or more
manufacturing
processes. The form of product in stage 12A can be an automobile in
production, a television
in production or an article of clothing in production, just to name a few
possibilities. In
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processing station 16, for example, the product in stage 12B can be inspected
for quality
assurance. Although the inspection can be thorough, there is no comprehensive
and automatic
record which can be easily checked to assure that every single manufacturing
process to which
the product was subjected was, in fact, appropriately applied. In processing
station 18, the
product in stage 12C is, for example, in transit to a warehouse as part of a
distribution
channel. Finally, the product leaves the warehouse in stage 12D for retail
merchandising at
a point of sale. There is a certain measure of paper documentation which can
accompany
some products, for example the sticker on an automobile or an instruction
manual, but in the
end, as the product is finally ready to purchased by a consumer, there is no
single record of
the product's processing history.
Certain limited aspects of this situation have been addressed in part by the
KANBAN
system developed in Japan. Kanban means "label" in Japanese. In accordance
with the
system a paper label is associated with a product as manufacturing commences.
When the
product is sold the label is returned to the manufacturing unit. Production of
new products,
that is to replace those sold out of inventory, is based on the quantity of
labels returned. A
related system for tracking work in process (WIP) is continuous work in
process tracking
(CONWIP), which starts tracking at the end of processing. Neither system can
provide
information from each product process and neither can provide for electronic
or other
automatic reading and writing data from and to the label, nor is there any
provision for
automatically controlling subsequent processes. Finally, neither system
provides tracking or
control subsequent to the initial processing facility, which can have a
plurality of process
stations. In both systems, the variable information is effectively discarded
at the conclusion
of processing in any given processing facility.
There is a long-felt need to automatically establish a recorded history for
all of the
processes to which a product can be subjected, from initial manufacture to an
ultimate retail
sale, irrespective of where the processes are implemented, which record can be
accessed by
appropriate management at any stage of the product's processing history.
SUMMARY OF THE INVENTION
In accordance with the inventive arrangements, a read/write radio frequency
identification (RFID) tag is associated with a product. The tag records the
conditions of the
process and the specific information the process needs to know about the
product to perform
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the process. At each location representing application of a process, a data
store in the tag can
be interrogated by appropriate management. Interrogation can be implemented
through a
computer controlled communications network. Read/write RFID terminals at each
processing
station provide the basic communications interface between the associated tags
and the
processing stations.
At the end of each process, the tag is loaded with data that are the history
and the proof
of the process conditions. In addition the tag/product can interact with a
subsequent
processing station to modify the process applied by the processing station it
accordance with
the information stored by a previous processing station. The data stored in
the tag can
therefore provide information for the next process, for example, distribution,
retail sale, return
of the product and perpetual inventory after purchase. In addition to all of
the foregoing
advantages, the tag can also be used as an identifier for an electronic
article surveillance
system, to prevent shoplifting and pilfering from inventory.
A method for production and operations management, in accordance with an
inventive
arrangement comprises the steps of: associating a read/write RFID tag with a
product to be
processed; subjecting said product to at least one process; and, writing
information to said
associated tag relating to said at least one process, whereby application of
said at least one
process to said product can be confirmed by reading said information from said
associated tag.
The method can further comprise the step of reading from said associated tag
said
information relating to said at least one process.
The method can also further comprise the steps of: subjecting said product to
a further
process; reading from said associated tag said information relating to said at
least one process;
modifying said furtlier process in accordance with said read information; and,
writing further
information to said associated tag related to said further process.
The at least one process and the further process can be at least one of a
manufacturing
process, an inspection process, a shipping process, a warehousing process and
a retailing
process.
A method for managing processing of a product subjected to a succession of
product
processes, in accordance with a further inventive arrangement, comprises the
steps of:
associating a read/write RFID tag with said product; and, writing information
to said tag
related to said product processes.
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The step of writing said information to said tag can be implemented upon
completion
of each said product process.
The method can fiuthe"r comprise the step of reading from said associated tag
said
information related to said product processes.
The writing step can comprise the steps of: writing information indicative of
completing said product processes; and, selectively writing control data for
subsequent
product processes onto said associated tag.
At least some of said control data can be written prior to said succession of
product
processes.
One or more of the processes can be modified in accordance with said read
information, particularly the control data.
The product processes can include at least one of a manufacturing process, an
inspection process, a shipping process, a warehousing process and a retailing
process.
A system for processing a product, in accordance with another inventive
arrangement,
comprises: a read/write RFID tag associated with said product; a plurality of
processing
stations; a process controller operatively associated with each said
processing station; an RFID
reader/writer operatively associated with each said processing station for
transferring data
between said process controller and said associated tag; a tag controller; a
first network
enabling communications between said tag controller and each said process
controller, each
said process controller being responsive to control data transmitted by said
tag controller and
transferred from said associated tag; and, a second network enabling
communications between
said tag controller and at least one management center controller, whereby
processing of said
product can be monitored and controlled by said at least one management center
at each said
processing station, irrespective of the nature and location of the processing
stations.
The processes performed at said processing stations can include at least one
of a
manufacturing process, an inspection process, a shipping process, a
warehousing process and
a retailing process.
The at least one management center controller can comprise at least one of a
manufacturing controller, an inspection controller, a warehouse controller, a
shipping
controller and a retail point of sale controller.
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According to one aspect of the present invention,
there is provided a method for production and operations
management, comprising the steps of: associating a
read/write RFID tag with a product to be processed;
subjecting said product to at least one process; and writing
information to said associated tag relating to said at least
one process, whereby application of said at least one
process to said product can be confirmed by reading said
information from said associated tag.
According to another aspect of the present
invention, there is provided a method for managing
processing of a product subjected to a succession of product
processes, comprising the steps of: associating a read/write
RFID tag with said product; and writing information to said
tag related to said product processes.
According to still another aspect of the present
invention, there is provided a system for processing a
product, comprising: a read/write RFID tag associated with
said product; a plurality of processing stations; a process
controller operatively associated with each said processing
station; an RFID reader/writer operatively associated with
each said processing station for transferring data between
said process controller and said associated tag; a tag
controller; a first network enabling communications between
said tag controller and each said process controller, each
said process controller being responsive to control data
transmitted by said tag controller and transferred from said
associated tag; and a second network enabling communications
between said tag controller and at least one management
center controller,
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whereby processing of said product can be
monitored and controlled by said at least one management
center at each said processing station irrespective of the
nature and location of the processing stations.
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BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1-3 sequentially illustrate a read/write cycle, in accordance with the
inventive
arrangements, for an RFID tag associated with a product being processed.
Figure 4 is a diagram of a read/write RFID tag used in accordance with the
inventive
arrangements.
Figure 5 is a block diagram illustrating a communications and control
arrangement in
accordance with the inventive arrangements.
Figure 6 illustrates the different communication paths for information in
accordance
with the inventive arrangements.
Figure 7 is an illustration useful for explaining prior art product
processing.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the inventive arrangements, a read/write RFID tag is
associated
with a product during processing. Processing is used broadly herein to denote
any change to
a product, including but not limited to manufacturing processes, inspection
processes,
distribution processes, shipping processes, warehousing processes and retail
processes. Any
change in a product, including but not limited to physical structure,
appearance, movement,
location, custody and ownership is a process which can be tracked in
accordance with the
inventive arrangements, by storing information on a read/Vrrite RFID tag
associated with the
product, and by reading the information from the tag and routing the
information to various
process managers or management structure. Although many different kinds of
processes are
identified herein as examples, the processes shown in the drawings are deemed
to be generic
processes for purposes of explaining the inventive arrangements. Similarly,
although many
different kinds of products are identified herein as examples, the products
identified in the
drawing are deemed to be generic processes for purposes of explaining the
inventive
arrangements. Although there are probably some products which by their nature
can defy
practical association with a read/write RFID tag during processing, as a
practical matter, the
inventive arrangements are nevertheless deemed to be universally applicable
for all products
and processes.
The inventive arrangements include a methodology that provides a connection
between the processes themselves, using the tags associated with each product
as a
communication and information storage media. Use of the term product herein
generally
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refers to one or more products. The tag carries the information concerning all
the processes
that the product is subjected to. In addition, the information can represent
the conditions of
the processes and how the processes affect the products.
The read/write RFID tags are associated with each product to be processed. The
tag
can contains fixed data, for example bar code and SKU identifiers, and
variable data that can
reflect the evolution of the product through a succession of processes.
Variable data can be
erased when the information is no longer needed.
Figure 1 shows a processing station 30 having a process controller 32. The
processing
station subjects a product 34 to a process n, wherein n indicates that the
process n can be the
first, last or any intermediate processing step in a succession of processes
to which the product
34 is subjected. Entry of the product 34 having a read/write RFID tag 36
associated therewith
into the processing station 30 is represented by arrow 38. The tag is shown in
more detail in
Figure 4. As a standard RFID tag, tag 36 comprises a data store 40 and an
activated electronic
article surveillance element 42. The data store 40 can contain fixed and
variable information.
In Figure 2, information from the data store 42 in the tag 36 is communicated
to the
process controller 32, represented by arrow 46. This information can be used
to control or
modify the process, or can simply confirm that a prerequisite processing step
has been
successfully performed. The actual processing to which the product is
subjected is
represented by arrow 48. The process n can include manufacturing, inspection,
distribution,
shipping, warehousing and retailing, in accordance with the non-limiting
examples noted
above. The implementation of process n can result in a change in product
structure,
appearance, movement, location, custody and ownership, in accordance with the
non-limiting
examples noted above. The information in the data store can be written during
or after
completion of a preceding process or even before any processing is undertaken.
If the product
is an article that can be painted in a variety of colors, for example, the tag
can include control
data for a paint processing station which specifies the color to be applied to
the product. Upon
completion of processing, information can be written to the tag confirming
that the product
was painted with the specified color.
In Figure 3, process n has been completed, and information relating to
completion of
process n is communicated from the process controller back to the data store
40 in tag 36,
represented by arrow 52. The product 34, which can be thought of as having
evolved through
the implementation of process n, leaves the processing station 30 as indicated
by arrow 54.
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The information in the tag 36 has been updated to reflect completion of
process n, and can
include one or more instructions, in the form of control data, for use by
subsequent processing
stations.
The fixed data concerning the product which can be stored in the tag can
include, for
example and without limitation, product identification, which can include:
name; family;
weight; and, size. The variable information concerning the product which can
be stored in the
tag can include, for example and without limitation: durability date; warranty
date and
conditions; and, special manufacturing orders. Information provided by the
processing
stations, concerning the process to which the product was subjected, can
include, for example
and without limitation: process plan identification; process n identification;
type of process;
batch number; date of process; duration of the process; waiting time between
processes; and,
noteworthy process conditions and incidents, for example over-time and over-
temperature.
Figure 5 is a block diagram illustrating a communications and control
arrangement in
accordance with the inventive arrangements. A processing station 30 having a
process
controller 32 corresponds to that shown in Figures 1-3. A product 34 having a
read/write
RFID tag 36 associated therewith is being subjected to process n. A radio
frequency (RF)
reader/writer 66 com.municates with the tag 36 by an RF link 68. The
read/writer 66 also
communicates with a tagging communications backbone 72 through an industrial
controller
and protocol converter 70. The process controller 32 communicates with the
industrial
controller and protocol converter 70 by a link 58 which can be an RS232/485
link or a TCP/IP
link.
Each industrial controller automatically processes all functions or
applications that are
required to communicate with the processing stations and the control and
management
networks. The main characteristics of the industrial controller is to
distribute the processes
and the databases inside the buildings close to the diversified sensors and
the actuators.
Sensors can include, for example: smoke detectors, RFID readers, tag readers,
access card
readers and other sensors associated with the processing stations in which the
product is
subjected to processing. Actuators can include, for example: conveyors,
industrial robots,
electric door locks, lights and sirens. Automated functions or applications
can include, for
example: access control, building management systems, electronic asset
surveillance, article
sensing and tracking, video switching, audio switching and performance
analysis.
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Each industrial controller uses a peer to peer communication and can
communicate
with any other industrial controller without host. Each industrial controller
is inter-operable
can implement co-processed functions between diversified applications. Each
industrial
controller is also inter-operable with other system provider's applications,
for example: audio,
video, access control, building management systems and RFID.
The communications backbone 72 communicates with other industrial controllers
and
protocol converters 74 and 76, for example by a TCP/IP line 78. The
communications
backbone 72 enables links between each of the processing and tagging
components described
above and an intelligent tagging application 80 running on a computer 82.
The intelligent tagging application 80 also communicates with a second
communications backbone 84, denoted a corporate backbone. The communications
backbone
84 enables communications between the intelligent tagging application 80 and
each of, for
example, a corporate mainframe computer 86, a manufacturing management
computer 88, a
warehouse management system computer 90 and other applications 92. The
communications
backbone 72 forms a first communications network 62 and the second
communications
backbone 84 forms a second communications network 64.
The two networks 62 and 64 enable information and control data to be
transmitted
between any components on either ofthe communications networks. Several
communications
paths are delineated for purposes of illustration. Information passes between
the tag 36 and
the process controller 32 by or through components 58, 70, 66 and 68.
Information passes
between the tag 36 and the intelligent tagging application 80 by or through
components 68,
66, 70 and 72. Information passes between the process controller 32 and the
intelligent
tagging application 80 by or though components 58, 70 and 72. Information
passes between
the tag 36 and the corporate mainframe 86 by or through components 68, 66, 70,
72, 80 and
84. Information passes between the process controller 32 and the manufacturing
management
computer 88 by or through components 58, 70, 72, 80 and 84.
Figure 6 illustrates process to process communications, process to product
communications and product to process communications in a global processing
operation 100.
Implementation of these communications can be accomplished by the
communications and
control network 60 illustrated in Figure 5. Global processing operation 100
comprises a
processing station 102 for implementing process 1, a processing station 104
for implementing
process 2 and a processing station 106 for implementing processes n. As a
practical matter,
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most global processing operations will comprises tens or hundreds or even
thousands of
processing stations. Moreover, as explained in connection with Figures 1-3,
the processing
stations can be scattered across the planet, and can be the virtually any
process, from and
including manufacture to retail sale, and even beyond, insofar as product
warranty processes
subsequent to sale can be encountered. In Figure 6, a product in a form 110A
is subjected to
process 1 in processing station 102. Information from the product, that is the
RFID tag 36,
is communicated from the tag 36 to process 2, as illustrated by arrow 112.
This information
can include, for example, batch number, lot number and size of the lot. The
product in a form
110B is subjected to process 2 in processing station 104. Information is
communicated from
process 2 to the product, that is the tag 36, as illustrated by arrow 114.
This information can
include, for example: product identification, which can include name, family,
weight and
size; durability; warranty date and conditions; and, conditions of
manufacturing, handling,
shipping history (date, duration) and storage history (date, duration).
Information is
communicated from the product, that is the tag, to process n as illustrated by
arrow 116. This
information can include, for example: product identification, which can
include name, family,
weight and size; durability; warranty date and conditions; and, conditions of
manufacturing,
handling, shipping history (date, duration) and storage history (date,
duration). The product
in a form I IOC is subjected to process 106. Eventually the product is
complete in a form
110D. In each processing stations, the various kinds of communication
described aL=ove can
take place. Moreover, thought the global processing operation 100 the various
processes can
be monitored by appropriate management applications and control data can be
supplied to the
processing stations from the appropriate management applications.
The inventive arrangements provide numerous benefits in the areas of
performance,
real time process control and quality. The standard productions systems
(command and
control) determine if a task is achieved. However, the real aim should be to
verify and prove
at any time that the process is in a correct evolution, and if the objective
performance is close
to the expected or perceived performance. In other words, in accordance with
the inventive
arrangements, the difference can be determined between the actual performance
and the
programmed or forecasted performance or the effective utilization ratio in a
warehouse. The
difference is counted and recorded to determine in real time the performance
ratio. This ratio
is the inverse of the deficiency gap, or the lack of performance.
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The inventive arrangements can provide a view in real time of the entire
process
because the monitoring network knows where the products are and what their
actual status is
as works in process. The perpetual inventory can be more accurate because the
information
concerning the products that are works in process can be integrated with the
inventory of the
finished products. All products will be appraised at the right cost.
The feedback enables real-time production decisions and plan changes,
increases the
visibility of problem situations, and provides a better prediction of
production levels. A
synchronization can be achieved between the processes and the management
control which
integrates the production and operations system, including manufacturing,
logistics and
distribution operations.
Quality of the product with respect to manufacturing quality standards can be
continuously monitored throughout production and many other kinds of
processing, and
always be available.
