For production and assembly: order-related and error-free replenishment

How do you check that a certain semi-finished product is intended for the next production step? Or which screws are needed when and in what quantity on a machine to process an order? A good replenishment control system must function according to demand, i.e. just-in-time and error-free. Ideally automated.
The aim is to prevent machines being incorrectly loaded and the production flow coming to a standstill. Automatic identification and checking of C-parts with RFID for a specific production step eliminates human error. A digitalized Kanban system like this makes your replenishment control efficient and prevents production downtimes.

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Meeting delivery deadlines and avoiding material bottlenecks

With an electronic, i.e. e-Kanban system, the exact parts required are brought to the production line. This also reduces expensive safety stocks in the warehouse. As used materials are reported directly to the ERP system via the warehouse management system, repeat orders are also triggered automatically.
The aim of intralogistics for production: To be able to deliver at all times.

Your production management, controlling, sales and purchasing benefit from:

  • Just-in-time delivery:
    The needs-based supply of materials ensures smooth production processes.
  • Reduction of excess stock:
    Buffer stocks in the warehouse become superfluous. Use storage space more efficiently and cost-effectively.
  • Adherence to delivery dates:
    Optimized replenishment control and the automated triggering of repeat orders guarantee that production and therefore delivery deadlines are met on time. For your customer satisfaction.
  • Supplier connection:
    Automated reordering directly from the supplier.
  • Digitalization in logistics and production:
    RFID-based parts identification as the basis for transparent inventory management, automated replenishment, IOT and other manifestations of Production 4.0.
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RF KonSys module replenishment

The identification options range from RFID labels and barcode labels on production parts to RFID transponders on load carriers, KLT containers and boxes. The latter can be “digitally married” to their contents, i.e. the parts in the box are identified via the box’s RFID transponder.
For uniform production, stationary readers at defined points are suitable, whose antennas recognize the parts and verify them for the production step. Shelf antennas are used in Kanban systems to detect and automatically book out parts during picking. Stationary barcode reading units can also be combined well here.

The RF KonSys Replenishment module solves these tasks:

  • Automatically reports replenishment requirements
  • Detects fluctuations in demand at an early stage
  • Verifies parts before assembly on the machine
  • Captures data in real time
  • Automated quality assurance
  • Creates a single view of the inventory (on the conveyor belt, WMS, ERP)
  • Optimizes material cycle for operators / systems
  • Reduces high stock levels
  • Ensures that delivery deadlines are met
We issue the visual and / or acoustic test signal where your employees need it: Either directly at the machine, on the production line or at the control station. For example, the quantity differences for reordering are displayed there.
In addition to the classic connection to WMS and ERP systems, the RF KonSys replenishment control module can also be integrated into your machine  control system. In this case, the machine actively “requests” the parts inspection from the user before a production step.

When the worker scans a component for assembly, he can now be sure that it is the right part.
There is no faster and more reliable check.

Head of quality assurance in the “final assembly” project

Application examples

The replenishment notification received in the warehouse only includes the parts currently required for the production line. Once these have been booked out in the warehouse management system (WMS) and transported to the production station, they are identified for this production step using RFID.
At the same time, the WMS automatically triggers an inventory report for the used parts in the ERP. The aim is to avoid material bottlenecks.

Before C-parts are fed into a machine, RFID identification is used to check whether the parts are approved for this production step. This ensures that no incorrect or faulty components enter the production process. The same process is used in assembly. The worker scans (himself or via an RFID reading station) the container with the components to be assembled and verifies them for assembly.

Industry
Empty Kanban containers trigger orders for the parts defined in the box in a special shelf equipped with RFID shelf antennas via the ERP system. This allows you to organize a time-optimized delivery cycle.

RFID creates the basis for an optimal production cycle and smooth intralogistics.
The radio-controlled identification of all parts, components, semi-finished products and finished products gives you inventory transparency that allows you to remain agile in production at all times.
A real-time view of parts that are currently being used, reordered or in stock provides you with reliable data for your decisions.

Case Studies | References

Inventarverfolgung Schiffs Hotellerie - RFID Konsortium

Cruise Inventory

Inventory in the cruise hotel industry

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available modules
Pharmalabor Sample Management mit RFID - RFID Konsortium

Pharma Research

Material Track & Trace in pharmaceutical research

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available modules

How does your replenishment control system benefit from the RF KonSys module?

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RFID-based replenishment

  • Time: Optimal machine utilization

  • Safe: No incorrect placement on machines, correct parts per production step

  • Automated: Inspection of production parts per production step

  • Flexible: production thanks to 100% material stock transparency

  • Deliverable: meeting deadlines

  • Storage efficiency: reduce storage costs

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Manual replenishment process

  • Delays: In production

  • Unsafe: Without reliable material verification, incorrect assemblies or the supply of faulty C-parts can occur

  • Error-prone: The paper-based Kanban system implies human error

  • Non-transparent: stock levels without reliable real-time data

  • Supply bottlenecks: Due to stock shortages

  • Storage costs: due to material buffer stocks

Conclusion

Our replenishment solution is perfect for manufacturing companies and their intralogistics.
Available solutions:

  • E-Kanban
  • Just-in-time delivery Production
  • Material flow
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We discuss individual solutions for your automated replenishment control.