Only flawless truck air filters are approved for OEM
The project
- Incorrectly produced goods reach the customer
- High number of complaints
- Averting the threat of contractual penalties
The solution
- RFID-controlled and integrated PLC-controlled production
- Direct quality assurance on the production line
- Multiple checks of each air filter: in production, at the packing station and in shipping
Key Facts – The Goals Achieved
Only faultless goods leave the warehouse
Serialization at item level, traceability of each individual air filter
Batch documentation obligation
High error rate reduced to zero
Avoid consequential damage where the filters are used: In the truck
Customer loyalty realized
Project Requirements
- Zero-defect strategy
- Serialization and tracking at item level
- Obligation to document batches
Special features:
The aim of this special project was to identify and sort out faulty commercial vehicle air filters early on in the production process. The special feature was the close integration of machine production and the RFID-based serialization of each individual air filter produced. As soon as a new RFID tag has been produced and affixed to a semi-finished product, the RF KonSys quality assurance module gives the signal that the machine may start production.
This ensures that all parts are labeled with an RFID tag. Subsequent processing stages such as screwing, welding and packaging are individually secured via RFID read points. Once sorted out, a part can no longer enter the production process. The special feature: All parts are monitored, whether they are correct or defective. The integration of the RFID reading processes with the production machines was a special feature of this project.
The challenge here was the exact timing when receiving the signals. RFID reading could only take place during a short time window within a production step.
Implementation of key objectives:
- The supplier of automotive air filters can now guarantee its customers: All parts are correct and do not cause any subsequent faults
- Customer confidence restored through quality management
- High error rate reduced to zero
"We use RFID for production monitoring and control the correct production sequence via RFID.
Defective parts do not even enter production.
RFID is an essential part of our quality management"
Head of filtration systems in the "truck filter production" project
No more thick air
If the customer's promise is not kept, especially when it comes to product quality, the result is expensive complaints. The air between customer and supplier is thick! The international market leader for filtration products therefore revised its quality management. The entire production process was to be secured via RFID and 100% quality was to be achieved for every article. The result: RFID readers now check every single filter at the screwing, welding and packing stations before it reaches the next processing stage. Detection in the RFID tunnel is the safest method for tight production environments, as it avoids so-called cross reads (unintentional reading processes). More quality assurance is not possible.
RF KonSys modules
RFID hardware
- RF KonSys Tunnel
- Kathrein RRU 1400 with Kathrein WIRA and Time7 antennas
RF KonSys modules
Monitoring
Track & Trace
Quality Assurance
RFID hardware
- RF KonSys Tunnel
- Kathrein RRU 1400 with Kathrein WIRA and Time7 antennas
Workstations
Transponder
Printer
RFID tunnel
