Professional Documents
Culture Documents
Ronny Higberg
Goran Larsson
2016
Ronny Higberg
Goran Larsson
2016
KEYWORDS: Bosch Rexroth, Cyber-Physical system, CPS, i4.0, Implementation, Industry 4.0,
Internet of Things, IoT, Lead time, Logistics, Manufacturing, Production, Radio Frequency
Identification, RFID, Smart factory.
Sammanfattning
I en alltmer hårdnande global konkurrens mellan industrier tilltar kravet på ökad produktivitet,
avkastning och kvalitet från internationella företag. Detta skapar ett behov av flexibla organisationer
som har rätt verktyg för att utveckla mer effektiva processer, minska kostnader och öka produktiviteten
inom tillverkande industrier. En ny våg inom industrin, omnämnd som nästa stora industriella revolution,
Industry 4.0, är på väg för att möta dessa nya utmaningar. Denna revolution syftar på sammankopplingen
av Internet med industrimiljöer, vilket leder till skapandet av smarta fabriker. I den smarta fabriken
sammankopplas funktioner inom logistik, tillverkning och produktutveckling i Cyber-fysiska system.
Ett sätt att skaffa sig ett övertag i en hårdnande internationell konkurrens är att få kontroll över det interna
värdeflödet. Tekniker som Radiofrekvensidentifikation (RFID) kan användas för att skapa smarta
fabriker där en produkt kan sända information om sin position i realtid. Detta examensarbete studerar
hur RFID kan användas för att uppnå Industry 4.0 genom en implementering i intern logistik på Bosch
Rexroth i Mellansel. Detta examensarbete syftar till att bidra med en djupare förståelse för hur en
implementering av RFID bör utformas och vad det kan bidra med i en tillverkande industri. Detta
examensarbete undersöker också hur en smartare industri kan uppnås med avseende på Internet of
Things och Industry 4.0 genom en fallstudie på en implementering av RFID i intern logistik.
Detta examensarbete är baserat på en litteraturstudie och empiriska resultat från fallstudien. Insikterna
från denna forskningsansats har använts för att svara på forskningsfrågorna i avhandlingen. Fallstudien
består av en kartläggning av nuläget, analys, systemdesign och implementering, och slutar med en
utvärdering av resultatet. Denna avhandling presenterar ett ramverk som beskriver stegen en
implementering av RFID bör genomgå. Faktorer för att uppnå en lyckad implementering diskuteras
också vidare. En sammanställning presenteras sedan över de fördelar en organisation kan uppnå genom
en implementering av RFID i intern logistik. Slutligen presenteras de fördelar Bosch Rexroth i Mellansel
kan uppnå inom Industry 4.0 genom en implementering av RFID.
NYCKELORD: Bosch Rexroth, Cyber-fysiska system, CPS, i4.0, Implementering, Industri 4.0, Internet
of Things, IoT, Ledtid, Logistik, Produktion, RFID, Smart fabrik, Tillverkning.
Abbreviations and Explanations
Abbreviation Explanation Expression Explanation
id Identification
JIT Just-in-time
1
INTRODUCTION
2
INTRODUCTION
insights are based on. The ninth chapter presents The division of work on the thesis report is
the final results of the thesis. It consists of both presented in Table 1. It does not specify which
theoretical, empirical and general insights gained section of this report that has been written by
during the thesis. Chapter ten presents the which person, instead it shows the division of
conclusions of the thesis. The conclusions are work in terms of responsibility of section. This
presented to answer the research questions means that the distributed person for each section
presented in the thesis objectives. The final of the report is responsible for the content of each
chapter presents a discussions on the results of section. The content is nevertheless written by
this thesis. Here the relevance, and the reliability both authors.
and validity of the results are discussed. The
Table 1: Division of work, according to report
chapter ends with suggestions on further research.
content.
1.5 The Authors Content Responsible
This thesis is written by two students, Ronny Introduction Larsson
Higberg and Goran Larsson, studying towards a
Master of Science degree in Industrial design Context Larsson
engineering. The Master Programme is a Theoretical framework Both authors
testament of an engineer that understands the
requirements of a product and how these affect Method Larsson
the demand on the manufacturing industry. An Current state Larsson
industrial design engineer also uses their
knowledge in production planning, work place Situational analysis Larsson
analysis and management to improve and RFID Design Higberg
optimize organizations. The workplace is seen as
a whole system containing many parts needing a Implementation Higberg
holistic approach for improving and maintaining Results Higberg
the edge in successful businesses. This holistic
way of approaching problems is the backbone of Conclusions Higberg
the Industrial Design Engineer Programme. Discussion Higberg
3
INTRODUCTION
4
Context
2 CONTEXT
To make sense of the case study one must also understand the context in
which the problem is formulated. The context to this thesis describes the
company Bosch Group, the Bosch Rexroth plant in Mellansel and the
manufactured product. The section is mostly derived from information obtained
via Bosch intranet such as product manuals, information wikis and other
related documents but also through interviews with the personnel working at
the plant.
5
CONTEXT
Figure 1: Visualization of the industrial revolutions. Based on material from Kagerman et al.
(2013).
6
CONTEXT
7
CONTEXT
8
Theoretical framework
3 THEORETICAL
FRAMEWORK
The theoretical framework describes relevant theories and analytical models
related to the research questions stated. This chapter aims to link the thesis to
existing knowledge, but also sets the foundation for challenging and extending
this knowledge.
9
THEORETICAL FRAMEWORK
thesis are two very commonly used time factors; raw material. This demand can both be internal,
cycle time and lead time. Cycle time is i.e. from other workstations, and external, as in
described by Bellgran & Säfsten as the time that the customer. This is sometimes described as
a product or component spends at each station, pull production, meaning that production is
or the time required to complete one cycle of an “pulled” based on this demand (Abdulmalek &
operation. Lead time is the time it takes between Rajgopal, 2007). Näslund (2008) describes JIT
the start and stop of a process, which usually is as an approach for redesigning production
used to describe the time between placing an systems. He further states that JIT was initially
order to delivery. a stand-alone methodology. Furthermore,
Näslund argues that Lean in some ways can be
Productivity can also be measured as a
described as an updated version of JIT. There
performance metric in itself. Bellgran & Säfsten
are however more modern versions of JIT used
(2005) describe productivity as the relation
as separate strategy. Green, Inman, Birou, &
between what has been achieved in the
Whitten (2014) mention total JIT as a separate
production (the output) and what was needed to
strategy, where the idea of pull production is
achieve it (input). An equation for productivity,
also applied on areas such as purchasing, selling
𝑃 , can also be presented as a factor or
and information.
percentage consisting of value adding time, 𝑡𝑣𝑎 ,
and the total time including stops, waiting time Kaizen is a philosophy within Lean Production,
etc., 𝑡𝑡𝑜𝑡 , formulated as where the organization strives for continuous
𝑡𝑣𝑎 improvement. Bosch practices kaizen in the
𝑃= form of continuous improvement processes
𝑡𝑡𝑜𝑡 (CIP) (Scwenker & Müller-Dofel, 2013). An
organization working with kaizen strives to
create a culture of continuous improvement
3.3 Lean Production
(Näslund, 2008). Moreover Czarnecki & Loyd
Lean Production is a management model where (2001) argue that visual tools are important to
the focus is to systematically remove waste from use in a factory setting. The authors mean that
all areas of the value stream. The value stream operators should have access to visual
can be described as the flow of all value-adding information on the process as one tool to
activities within a process or system. Lean identify areas for continuous improvements.
production is used by Bosch Rexroth in a
localized variant called Bosch Production 3.3.1 Kanban
System (BPS) (Robert Bosch GmbH, 2016). The
effects that an organization with Lean Kanban is a philosophy that plays a significant
Production strives for are increased efficiency, role in the JIT production system. The Japanese
decreasing costs by eliminating non-value steps word Kanban, translates to “signboard” and is
and inefficiencies in the processes, reduced generally accepted as a tool for demand
cycle times, and increased profit for the scheduling. It was created to control inventory
organization (Näslund, 2008). In Lean levels by managing the supply of components in
Production, seven wastes are listed. Hines and the production. A Kanban system is used at the
Rich (1997) recapitulate the wastes MllP plant to create a pull effect in the
incorporated into Lean Production as: (1) transportation of materials. (Gross & Kenneth,
overproduction; (2) waiting; (3) transportation; 2003; Kumar & Panneerselvam, 2007).
(4) inappropriate processing; (5) excess With Kanban, visual signals are used to
inventory; (6) excess motion; (7) defects. determine production to fill demand on the
Just-in-time production (JIT) is a tool principles of pull production and JIT. The
commonly associated with Lean Production. JIT system is based on inventory level or material
means that the production is managed through scheduling. Kanban is usually represented by a
customer demand backwards to the ordering of card containing information about a product’s
manufacturing information and details of its
11
THEORETICAL FRAMEWORK
path to completion (Kumar & Panneerselvam, the introduction of Internet in industries. This
2007). For a system to be considered as true leads to the introduction of the concept of Cyber
Kanban, Gross & Kenneth (2003) state that the Physical Systems (CPS). Functions as logistics,
production processes it controls must; (1) only manufacturing and product development are
refill product(s) to replace consumed product(s) described by Kagerman et al. (2013) as
by its customer(s); (2) only produce based on integrated in the smart factory. Heng (2014) also
refill signal sent by its customer(s). Junior & states the importance of imbedding not only
Godinho Filho (2010) elaborate on this and state value adding processes but also working
that two Kanban communication signals (plastic organization, business models and services in
cards) are used in the original system; one to the strategy for i4.0. Johansson & Larsson
production that authorizes a process to produce (2015) mean that this approach leads to flexible
a fixed amount of products and one to production systems and organizations that can
transportation that authorizes transporting a quickly adapt to changing circumstances.
fixed amount of products downstream. The
I4.0 is described by Lasi et al. (2014) as
Kanban system leads to a decentralized control
introducing and evolving on functions as
of the production flow. Nevertheless, Kanban
autonomous machines, preventive maintenance,
scheduling does not replace material planning
remote control, energy supervision and
but rather uses that information to create a
optimization, and advanced diagnostic
Kanban card for visual control. It can be
functions. Kagerman et al. (2013) evolve on this
considered as an executional tool rather than a
and describe the revolution as being a
planning tool. Thus, the system creates a
realization of IoT. The foundation of IoT is the
situation where the work in progress, referring
development of technology in areas such as
to materials, is minimized between processes,
programmability, storage and data collection
leading to reduced inventory costs (Gross &
capabilities (also known as Big Data), and
Kenneth, 2003).
sensor-based functionality for machinery.
Kanban was created to fulfill specific needs at
I4.0 will also evolve the employees’ work
Toyota, and be effective under specific
routines. Kagerman et al. (2013) mention how
conditions. Since conditions vary between
an increased focus on real-time oriented control
organizations, the original Kanban system has
of processes will change both work duties and
some restrictions. Studies show that it is not
work environment. Manufacturing work has
adequate in situations with unstable demand,
been, and will continue to shift from largely
processing time instability, non-standardized
manual labor to programming and control of
operations, long setup time, great variety of
high performance machinery. This will increase
items, and/or raw material supply uncertainty.
the complexity of work, demanding an
Variations to the Kanban system were created to
increased focus in maintaining and fostering the
adapt properly to the organizations conditions,
skill level of employees. Routine tasks will be
due to the difficulty in using the original system.
handled by smart machinery, leaving room for
Most of the modifications proposed to the
more creative and value adding work. (EPRS,
original Kanban system are concerned with
2015; Johansson & Larsson, 2015)
signal use, and to establish means of
manipulating the number of signals or the The potential benefits of I4.0 are described by
quantity. The most important topics of Kagerman et al. (2013), Lasi et al. (2014) and
theoretical studies about Kanban systems are Lee, Kao & Yang (2014) as; (1) increased
how to determine the right number of signals. flexibility and shorter development processes;
(Junior & Godinho Filho, 2010) (2) increased ability in meeting customer
demand; (3) organizational improvements
3.4 Industry 4.0 through a more transparent industry; (4)
optimized use of machinery; (5) reduced labor
Lasi et al. (2014) describe I4.0 as the next big
costs and improved work environment for
industrial revolution. This revolution refers to
employees.
12
THEORETICAL FRAMEWORK
3.5 Radio Frequency Identification technology can lead to total traceability of all
products in the whole production system. The
One way to get control of inventory and
author also mentions that companies have been
logistics is by using automated id technology
actively using and developing RFID for many
together with checkpoints. The idea is to report
years and there are still organizations currently
the location of a product through its id-number
discovering new benefits of the technology.
whenever it passes a checkpoint (McFarlane,
Liukkonen further states that RFID can reduce
Sarma, Chirn, Wong, Ashton, 2003). This can
production costs in the future and therefore be
be achieved with i.e. RFID. RFID is a
an incentive for lower product prices. From this
communicational technology that can share
motive the improvement of RFID, especially
information via small transponders, and in that
when it comes to visualizing the information, is
way communicate with other technical devices.
going to be a major focus area in the evolution
Zheng, Fu & Yang (2012) regards RFID as one
of RFID technology.
of the key technologies for future automation.
According to Ting, Tsang & Tse (2013), gains
The principle of RFID as a tracking system, is
for organizations to use RFID systems are better
that the products or materials holding an RFID
inventory visibility, better supply chain
transponder also have unique id-numbers. The
visibility, increased productivity and labor
transponder can then communicate the object’s
efficiency, improved assets tracking, out-of-
unique id to a RFID reader connected to a local
stock reduction, increased security, inventory
database, where information about the product
reduction, cost reduction, better handling of
is stored. Information can also be stored in the
store and shelf inventory and an increase in the
product’s transponder to be read in another
ability to meet customer requirements.
workshop, at a retailer’s location or in other
McFarlane et al (2003) also mention greater
places outside the workshop. Castro Adaujo
product tracking accuracy, product diversions,
Filho, Travassos & Figueriedo (2011) states that
and faster checkout systems as possible gains
it is possible to read information on up to two
obtained through RFID. One big area for future
hundred transponders in a second with RFID
development is the large amount of collected
technology. When an RFID system is connected
data in RFID-reads of events. This can open up
to the Internet it can be seen as a component of
for new possibilities in i.e. statistical analysis of
smart factories and IoT. In that case the
processes or analysis of the relationships
transponder communicates through Internet
between events. RFID is thus a suitable
with a database located on a server. This means
candidate for the i4.0 coined term “Big data”.
access to an RFID system is possible to achieve
Today, algorithms for efficient ways of storing
from any location. (Zheng et al., 2012)
data through cleansing algorithms and similar
There are mainly three different types of RFID- already exist (Zhong, Huang, Lan, Dai, Xu,
transponders. Passive RFID transponders are Zhang, 2015).
transponders that do not need an internal power
Castro Adaujo Filho, Travassos & Figueriedo
source such as a battery. The passive RFID
(2011) experimented with RFID and found that
transponder uses power sent from the antenna to
transponders on metal surfaces increased the
relay information to an RFID-reader.
readability through reflection. To avoid
Consequently, a passive transponder is only
redundancy, the authors proposed and tested
active when it is inside the antenna field. The
solutions with either manual scanners or gates
two other types of RFID transponders, are active
where the RFID was read. Zhu, Mukhopadhyay,
and semi-passive RFID-transponders. These
Samar & Kurata (2012) tested different types of
transponders have their own power source
RFID transponders and also concluded that a
which makes them operable in a longer range.
transponder mounted on a metal surface makes
(Hervert-Escobar, Smith, Rodriguez-Cruz,
it more readable. Zhu and Cao (2014),
Cardenas-Barron, 2015)
investigated the usability of passive RFID
According to Liukkonen (2015), RFID transponders in different environments. Their
13
THEORETICAL FRAMEWORK
findings indicated that that metal surfaces can The third step, system design (3), should start
produce shielding effects which result in with an analysis of the requirements for the
unreadable transponders.
Ting, et al. (2013) also describe some reasons
organizations express for not implementing
RFID as; they perceive it as an immature
technology, there is a lack of return of interest,
there is not sufficient customer demand, there is
a lack of understanding the technology,
standards for RFID are perceived as inadequate
and implementation costs are high.
Sheng, Zeadally, Luo, Chung & Maamar (2010)
state that RFID is one of the most influent
technological innovations in the world and
recognized as one of the most powerful
innovations in terms of use. To be able to follow
this trend and respond to business needs, many
organizations have already adopted the RFID
technology and many more are on their way
(Mohammad et al, 2014).
systems can be identified. After possible system. Mainly because of the advantages in
problems are detected and solved in the long-distance and non-line of sight reading that
prototype testing phase, the actual is possible with RFID. Chen et al., claims that it
implementation can be done (5). In most cases is particularly suitable for tracking
the implementation includes changes in manufacturing sources in assembly and
management, work routines and system production of complex products.
deployment. Sometimes it is also possible to
Chen et al. (2012), designed a real-time value
develop the new (RFID) system parallel with the
stream monitoring system in an experimental
old system until it runs satisfyingly.
environment. By using RFID technology the
Ting et al., (2013), labels the last step in the system improved the traditional Value stream
implementation as continuous improvement (6). map (VSM) by tracking production flow in real
The authors believe that in a new system there time with data from real-time production. The
will always be room for further improvement. authors state that a value stream monitoring
Because of this, they suggest that the system with real-time information can support
organization continuously evaluate and improve management in making decisions by visualizing
the system. The improvement should also real-time data from the value stream.
include collecting feedback from users as one
In a case study of an industry production line,
basis for further development.
presented by Abdullah, Ismail, Halim, (2015),
Ting et al., (2013), also defines some critical the output of an RFID system was evaluated.
success factors for an RFID implementation. The findings of the study showed that a display
According to the authors there are three linked to the RFID system was the most
dimensions for the critical factors; the technical, efficient way to show status because of its
the managerial and the social dimension. The simplicity and cost-effectiveness. The display
technical dimension includes selection of the can show figures like targets, differences and
right hardware, effective testing, sufficient efficiency. The authors further proposed that the
technical support, understanding of the display should be located in a location close to
processes and clear performance measures. The the users for easy visual access of the current
managerial dimension is more focused on status of the production line. The simplified
project managerial skills, where risk functionality description of the display is shown
management, project management and a clear in Figure 6. The RFID reader together with the
vision of the project are important aspects. The database can be seen as the master of the system
social dimension focuses on the importance of a and uses the status information collected from
well-functioning teamwork and the use of the RFID transponders to display the present
effective communication. status of the production. (Abdullah, Ismail,
Halim, 2015)
3.5.2 Real-time Monitoring
According to Chen, Chen & Cox (2012) RFID
can, besides the autonomic communicational
benefits, effectively be used to improve
visibility and traceability in a manufacturing
Figure 6: Principal description of RFID and monitor (Based on Abdullah, Ismail & Halim, 2015).
15
THEORETICAL FRAMEWORK
16
Method
4 METHOD
The method chapter presents the tools and practices that has been used
during this thesis. This chapter aims to help the reader follow and understand
how the process of work was executed. It also helps the reader understand
how data was collected and used. This master thesis is founded on a literature
review and a case study done at MllP. Throughout the thesis a standardized
work method focusing on iteration has been used to approach each phase to
ensure a consistent progression of the work.
17
METHOD
18
METHOD
finishing tasks are repeated again. This can be The first crucial step in the project was to setup
compared with the Study step in the PDSA cycle. a project plan to establish the research questions,
This means progress through the phases of the project scope, and objectives and aims.
thesis have not been made in a straight-through Background to the project and important
process but rather in an iterative way. Working stakeholders were also defined and included in
through the tasks has been seen as a way of the plan. A rough structure for the project
generating more information on what is needed outline was establish as a preliminary guideline
as new information subsides. The described and overview of what would be accomplished.
cycle has been regarded by the authors as a This was also done to concretize the work and
means of efficiently “forcing” the work forward. objectives of the master thesis. Project
The step Act in the PDSA cycle can be management, in terms of resources like
compared with moving on to the next phase in available time, was also approximated and
the process of work for this thesis. delegated among the work process phases
thought relevant for the project. Lastly the
project organization and the means of
communication between the authors and
supervisors was proposed. The aims in
developing the project plan was to create a
guideline for the entire project and to
communicate this among all parties. The results
from the project plan have been updated and
incorporated into this report as the process of
work has progressed.
A standard way of presenting a time schedule is
to use a Gantt chart. The Gantt chart presents
activities as bars on a timeline and constraints
presented as lines between the bars. A Gantt
chart makes visualization of complex
scheduling possible (Tory, Staub-French,
Huang, Chang, Swindells, Pottinger, 2013).
The Gantt chart has been used in this project as
a way of constraining each phase the project has
progressed through by setting a target for when
a phase should start and be finished. The chart
has been updated two times during the thesis.
The first update was made somewhere halfway
Figure 7: The work process used in each phase of through the thesis. The changes here brought the
the thesis (Source: Compiled by authors). time table forward on the design phase and
implementation since work could be started
4.2.1 Project Planning earlier than expected. During the final month a
second edit was made where the implementation
The overall work process has been focused on a phase was extended because of a clarification of
great deal of planning to maintain a steady work delivery dates. The phase was also more clearly
flow and to fully consider all relevant factors of defined with points added such as training of
the current state at the case study, personnel and software setup. The Gantt chart in
implementation of hardware, education of its entirety can be seen in Appendix 1.
personnel but also the theoretical part of the
thesis. The planning has been an ever evolving The process of work on a weekly and daily level
process where steps have been added as the has been handled through an action log. This log
work has progressed. consists of several tasks with item numbers,
19
METHOD
Figure 8: Excerpt from action log showing week, task, owner, assigned and due dates, and status (Source:
Compiled by authors).
20
METHOD
4.2.4 Risk Assessment An Ishikawa diagram has also been used for risk
assessment, The Ishikawa diagram, also
Risk management can be considered a main commonly referred to as the cause-and-effect-
success factor in project management as stated diagram or fishbone diagram, is a visual tool
by Chan, Yeung, Yu, Wang, Ke, (2011) in a used to analyze a problem and its causes. The
study of risks in public-private projects in China. diagram is constructed of a box with the defined
In this master thesis a risk assessment was problem attached to a center line that is linked
initiated at the start. The assessment with an to boxes of major potential cause categories.
action plan for each risk can be seen in Table 2, Each category box has one or more underlying
where the severity and probability of the risk are causes linked to it. The method for creating the
approximated on a four-grade scale. The risk diagram is identifying potential major problem
score is calculated as a factor of the severity and areas and causes through brainstorming. The
probability. Two major risks were identified as diagram is useful for identifying potential
insufficient process mapping and insufficient causes to a problem for troubleshooting or risk
knowledge of software. The risks were revisited management (Montgomery, 2013).
halfway into the process of work and were then
In this thesis the Ishikawa diagram was used for
considered as not affecting the chance of
succeeding with the master thesis. The risks risk analysis in terms of potential risks for RFID
implementation. This helped identify areas that
remaining were related to the implementation.
needed consideration in the implementation
Regardless of the rate of implementation, the
collected empirical data were considered design. The method used for identifying
sufficient for contribution to the answers of the potential causes was brainstorming rooted in
data gathered from evaluation of the current
questions of the research questions.
state. The diagram was updated several times
during the work progress, as new insights were
learned.
Table 2: Initial risk assessment for master thesis with suggested actions to reduce risk.
21
METHOD
4.3 Literature Review The data collection phase for this thesis has
mainly consisted of visits and interviews in the
To lay a theoretical foundation to the work, a
production environment and workshops. Some
literature review has been conducted on
information like internal documents has also
scientific papers related to this thesis. The
been collected digitally through the internal
articles used for literature review have mainly
network.
been obtained through the databases Web of
Science 1 , Primo 2 and Scopus 3 at Luleå
University of Technology. Google scholar4 was 4.4.1 Observations
also used to find specific articles mentioned in Observations are generally used to develop an
other sources. To maintain high quality in the understanding of a situation and to collect
literature review, information has been information about different events. With
triangulated with several sources. Search terms observations it is possible to see how tasks are
used in these databases were formulated as or managed and how humans handle a machine or
directly related to “material handling”, “auto a product. An observation is done to gain deeper
id”, “industry 4.0”, “RFID”, “monitoring”, knowledge of the observed situation and
“implementation” and “value stream”. possibly show things that the user himself would
Selections of relevant articles were based on the not see. An observation may be done either in a
abstracts and conclusions from the search real work environment, such as at the work
results to get an idea of the articles’ relevance to stations at MllP, or in a fictitious environment.
this thesis. In some of the search results, new With observations it is possible to get both
relevant references and recurring authors led to qualitative and quantitative data depending on
new search terms. Through this iterative the set up for the observation. An observation
approach, further research could be done in can be systematic, which means that a specific
relevant areas.As a general rule, this report has task or event is observed. Observations can also
had the goal of using sources that are up to date, be unspecific where everything of interest is
meaning finding information at least not older observed. (Osvalder, Rose & Karlsson, 2010)
than five years. Some older sources have been Observations of the physical working station
used, but only on the argument that they are areas have been a crucial part of this thesis. The
regularly referenced to by other authors. entrance and leave of the motor have been
thoroughly observed at all stations to fully
4.4 Data Collection understand working routines when designing
Accurate data collection is essential to maintain the implementation. Passive observations have
a high quality to the research made in this thesis. also been carried out to get a “true” picture of
The selection of the appropriate tools for data the daily operations without disturbing or
collection is thus of great importance. To ensure influencing the operators. Basic processes like
the reliability in the collected data several leaving and collecting the motor with a forklift
different methods can be used, both qualitative is one example of processes were normal
and quantitative. The case study at MllP has observations in conjunction with interviews
been of an explorative nature which has laid a have given sufficient information for the current
lot of emphasis towards qualitative data. state analysis.
1 https://webofknowledge.com/
2 http://primo.lib.ltu.se/primo_library/libweb/action/search.do
3 http://www.scopus.com
4 https://scholar.google.se/
22
METHOD
Visits to the production environment have been out of the chambers. During testing,
carried out on an almost daily basis during the participatory observations were chosen as an
authors’ stay in Mellansel. Although all of these approach to identify potential sources of errors
visits have not had the clear agenda of observing that could be difficult to identify at a first glance.
operations, quick checks have frequently been These observations have been carried out by
carried out to see if new undiscovered activities visiting the related workstations at the start,
have taken place. This has led to the discovery during the test and at the end of the test.
of relevant information that may have been
difficult to perceive in advance when doing 4.4.3 Interviews
interviews with personnel. Iteratively,
information has also been gathered as the work An important factor in acknowledging the
has progressed and information gaps have correct needs for the case study is a correct
subsided. A more active observational approach understanding of the current situation at MllP.
has also been chosen through participatory One of the most important tools to achieve this
observations described in the next section. is by interviewing the people working in the
environment. Lantz (2013) describes that the
Disadvantages of observations as a tool for data way in which an interview is performed may
collection are that they usually do not show the give dissimilar data, describe different contexts
underlying reasons to the observed situation. It and give different results and conclusions. Lantz
is recommended to do complementary categorizes interviews into two main groups;
interviews in conjunction with observations to open and structured interviews. In an open
get information about cognitive factors and interview each interviewee is given open
better understand the situation. (Osvalder, Rose questions to freely elaborate on. Lantz considers
& Karlsson, 2010) this a good method for explorative information
gathering and understanding the context of the
4.4.2 Participatory Observations interviewee. In an open interview questions like
how something is perceived and what meaning
Osvalder et al. (2010), describe participatory
it has are asked. The role of the interviewer is
observation as an observation where the
described as being empathic and flexible. This
observing person(s) is involved in the work
interview method can be perceived as a
process and undergoes the studied operations
qualitative analysis tool because of its
himself to learn and build a deeper
subjective nature. Lantz also mentions a variant
understanding for the work task. The approach
of the open interview in the directed open
in this thesis has been to use participatory
interview. Here the interviewer directs
observations as a means of identifying factors
questions towards topics he or she considers
that may have been overlooked while making
important.
regular observations.
In a structured interview questions have been
Participatory observations were made on
formulated to catch the subject’s perception or
several occasions to observe manual working
experience of a predetermined topic. Lantz
routines at investigated process steps and to gain
(2013) considers having predetermined answers
knowledge on optimal hardware setup, as to not
to choose from as the most structured interview
disturb daily operations. Processes like how a
form. Structured interviews are focused on
transponder is attached to the motor and how
quantitative comparisons between interviewees
information is written to the RFID transponder
that cannot be achieved through open interviews.
have been observed together with the personnel.
Lantz states that a semi-structured approach on
This was done to analyse crucial steps in the
interviews can be achieved. Here the subject is
current state and for writing new work routines
asked to describe his or her perception of a set
when implementing the new RFID system.
of predetermined questions. This approach can
Observations have also been made on the testing
be described as involving both open and closed
chambers to see how the operators walked
answers. The interviewer gets results that can be
around the station and moved the motors in and
23
METHOD
used for quantitative analysis but also a limited Both workshops were divided into two sections.
possibility of qualitative analysis. As described The first section was an introductory part,
by Lantz, qualitative analysis can give an handling information on the project, all areas
opportunity to understand new phenomena and affected in the production and examples of
modify established research on areas. everyday use of RFID technology to setup the
Quantitative analysis give knowledge on stage for the workshops. The second part was a
relations between phenomena to be able to draw two-way communicational dialogue used for
conclusions based on data. idea generation, problem identification and
discussion of possibilities. A theme consisting
As a means of doing an explorative analysis for
of three questions was used as the basis for the
this case study, a semi-structured approach on
discussion. The authors to this thesis played the
the interviews have been chosen as the main
role of leaders of the workshop, to initiate and
interview form. Interviews with people at LOG,
moderate the discussion when needed. Ideas and
MOE and other departments not directly on the
discussions were continuously written down
shop floor have been booked with a clear agenda
during the sessions. Each workshop session was
to the interviewee(s) from which the subject
45 minutes long. The workshop setup can be
have evolved. All planned interviews can be
seen in Appendix 3.
seen in Appendix 2.
The operators and manual workers at the shop 4.5 Data Analysis
floor have been interviewed at their respective
Analysis of data is the process following data
stations to map out their working and reporting
collection. It has been used to probe data for
routines. These interviews have been semi-
useful information to suggest conclusions and
structured or almost unstructured in nature as to
support decision-making in the phase for
not filter out information that could prove
conceptual design. Much of the analysis work
crucial to the implementation. This means
done in this thesis can be seen as a sort of data
undertaking unplanned interviews on the shop
cleaning or processing to obtain the correct
floor when the manual workers have been
information. The general approach has been to
available. This approach of explorative
always triangulate data with several sources as
interviews has been used to confirm information
a basis for understanding what is and what is not
about workstations and to become aware of the
relevant. Data analysis has in many ways also
possibilities from the manual workers point of
been a process of analyzing and presenting
view.
results to the stakeholders for confirmation.
4.4.4 Workshops
4.5.1 Value Stream Mapping
Workshops have been chosen as a method to
Value Stream Mapping (VSM) is a Lean
generate and convey ideas among the personnel.
Production tool for mapping the value stream of
The workshops for this thesis have been held as
a process or value chain. This is done to identify
single short focused events. One workshops
and eliminate sources of waste and highlight
split in two sessions have been held with the
opportunities for improvement (Dotoli et al.,
operators working directly with the motor. The
2015). Abdulmalek et al. (2006) regard VSM as
topic was defined as how the implementation of
one of the most important and universally
RFID could improve the working environment
applicable tools for industries. In this thesis,
for the operators. A total of 30 individuals
VSM is used to visualize and analyze the value
participated in both sessions, coming from all
chain for related processes but also to identify
stations related to the case study at MllP. Two
potential spots for RFID implementation. It has
sessions were used to involve all related
also been used to convey conceptual designs and
personnel working on different shifts. At the
confirm the situational analysis with
second session, the shop floor manager also
stakeholders during interviews and meetings.
participated.
24
METHOD
5 https://products.office.com/en-us/visio/flowchart-software
25
METHOD
Installation has not been handled solely by the The reliability and validity of this master thesis
thesis group but collaborative with local can be considered as consisting of two factors:
consultants and Bosch Center of Competence the reliability of the methods selected as tools
for the thesis and the comparison between
(hereafter abbreviated CoC) for RFID in
theoretical and empirical insights. Methods
Germany. CoC are cross-divisional
organizational units which bundle resources and have been selected based on a clear
know-how (Robert Bosch GmbH, 2015c). understanding of what the tool can achieve in
this thesis, which is described in the previous
The installation phase can be described as sections. Selections of multiple methods have
consisting of the installation of hardware at also been chosen to strengthen the results, which
locations in the plant and the setup of the is supported as a reliable method for obtaining
software. validity according to Yin (2013). These methods
have also been of different types to get varying
4.7.2 Testing data types to base the results on. The main
method of work has been focused on using both
Several tests were performed on equipment and theoretical and empirical findings to create
software setup to assure that every step of the reliability to the thesis, described as the Logic
implementation was possible. An initial test was model by Yin. This model is described by Yin
made to assure that the attachment of the RFID as providing validity to the results by comparing
transponder could be made in the first step of the the results with existing studies.
VSD without any complications in subsequent
processes. After installation, functionality tests The reliability and validity was also ensured by
were also performed to fine-tune equipment and working in a cyclic pattern described in 4.2
to optimize implementation setup. These were Process of work. Since each undertaken action
done by testing a transponder with written was confirmed as completed first after it was
information and tweaking settings until evaluated, a greater quality to the work and a
consistent reads could be achieved. more valid result could be reached. One main
method for validation has also been to discuss
working methods and results with different
stakeholders i.e. the sponsor, the university
supervisor, operators working in the factory and
other personnel at LOG and MOE.
26
Case study miip: Current State
27
CASE STUDY MllP: CURRENT STATE
Figure 9: Plant layout with offices removed (Source: Compiled by authors from existing plant layout).
28
CASE STUDY MllP: CURRENT STATE
washing is done by automated rollers that start variations in the painting process for every
running when the washing has an empty slot. motor. All the transports in the painting area are
The automated washing process contains also automated. When a motor is put in the
washing and cooling. Empty fixtures are painting area, the RFID transponder calls for
automatically brought outside by rollers for transportation from an automated guided
forklift collection. At the end of the workday, all vehicle (AGV). The AGV takes the motor
washed motors are manually reported having through the whole painting process without any
gone through washing in AX. human involvement in any of the process steps.
When the kit has been washed and cooled it goes After the painting process the motors are
into the assembly station for manual assembly. brought to the packaging area by the AGV.
Assembled motors are reported in AX and Packing is done in boxes or special pallets
brought through an automatic gate to the testing depending on CA motor model. When the
area. packing is done the motor is reported as ready
for shipping and placed in the inventory. CA
Every motor is being tested before it moves on
motors are both stored and reported as finished
to the painting area. The motor testing area
in this area (CA50/CA70) or after the motors
consists of a total of five testing chambers,
have been put in a storage tent outside the
suitable for the different motor models. Two
packing area. After the motor is reported as
chambers exist for the CA motor. The testing is
finished, the distribution process can be planned
done inside the testing chambers and consist
and the motor is ready to be delivered.
both functionality and strength tests. The test
results are linked to the motors ID and are stored,
5.3 Transponder Attachment
for either further analysis or for evaluating
component errors. The results are uploaded to Today, a double stitched RFID transponder,
AX. shown in Figure 11, is attached to the motors in
the assembly. This transponder is used for the
The paint shop is fully automated. The system
fully automatic paint shop where the processes
uses RFID transponders attached on the motor
and AGV communicate directly with the motor
to communicate and get information regarding
Figure 10: VSM of thesis related process (Source: Compiled by authors from Bosch Rexroth Mellansel internal
VSM).
29
CASE STUDY MllP: CURRENT STATE
on which painting procedure and color scheme The flow for the manufacturing group of
it is programmed for. processes is managed through two Kanban
systems to achieve pull production or JIT. The
transport Kanban cards are used to order raw
material to the manufacturing processes. This
Kanban system consists of order cards with
RFID transponders and a Milk run with a set
route and time table. The Milk run picks up
ordering cards at the stops for material refill and
returns with the ordered material at the next
scheduled route. The stops are located at their
corresponding manufacturing stations. There is
also production Kanban to control the
production of parts.
30
CASE STUDY MllP: CURRENT STATE
5.5.1 SAP For this project there are four different options
when choosing RFID readers. Single point
SAP is an enterprise system used to visualize readers are chosen when an id of an RFID
production, purchasing, maintenance and transponder can be read from the same point
disposition services. SAP is required within the every time. Gate readers are chosen when the
Bosch Group and is planned for implementation RFID transponder must be scanned when
at MllP in May 2016. It will replace the current moving between workstations and areas in the
software Microsoft Dynamics AX (Bosch plant. The third option is a reader with direction
Group, 2015). detection; this will be selected when the
direction of a moving RFID transponder needs
5.6 BOSCH Group Guidelines to be known. The fourth reader is a mobile
Bosch has several guidelines regarding choice reader for manual scanning. A list of different
of equipment and software in their plants. A RFID-antennas is showed in Appendix 4.
guideline for object identification also exists
within the company. These guidelines are 5.6.2 GS1
described in the sections below.
Bosch group follows the GS1 standard for
object identification. GS1 is an international,
5.6.1 RFID Equipment neutral and not-for-profit organization that
Bosch Group has set up a catalogue of preferred develops and maintains standards for businesses
RFID equipment, to make sure that all and organizations around the world (GS1, 2015).
installations will be compatible with the internal The used standard can be seen in Appendix 5.
systems and to meet Bosch standards.
31
CASE STUDY MllP: CURRENT STATE
32
Case study miip: Situational analysis
33
CASE STUDY MllP: SITUATIONAL ANALYSIS
34
CASE STUDY MllP: SITUATIONAL ANALYSIS
35
CASE STUDY MllP: SITUATIONAL ANALYSIS
36
CASE STUDY MllP: SITUATIONAL ANALYSIS
37
CASE STUDY MllP: SITUATIONAL ANALYSIS
38
Case study miip: Rfid system design
39
CASE STUDY MllP: RFID SYSTEM DESIGN
40
CASE STUDY MllP: RFID SYSTEM DESIGN
routines on the different locations. The selection Table 3: Results from the experiment.
of placement and chosen equipment was an
Transponders Pass
iterative process since a decision of equipment %
tested test
effected the physical placement and vice versa.
Experiment 1 5 2 40%
7.2 Hardware Testing
Experiment 2 5 5 100%
One issue mentioned among MOE workers was
if the RFID transponder could pass through the
washing process without falling off. A test was The experiment showed that if the attachment of
thus set up with the aim to investigate how the RFID transponders is moved to a station before
RFID transponder should be attached to the the washing operation, it will need pre-washing.
motor to pass the washer without any incidents.
The involvement from the operators in the test
The test was done in two parts with five test runs was to remove the transponder after the motor
for both experiments. A sample size was chosen had gone through washing. The operators also
together with a foreman at MOE, to make sure orally commented the results on how firmly the
that the test did not disturb assembly operations. transponder was attached or if problems had
The first experiment involved attaching the subsided.
RFID transponders on a motor component
without any pre-washing of the surface. In the
second experiment the surface on which the
transponder was attached to was pre-washed
with technical petroleum. The thesis group
manually attached the first three transponders.
This was done to show and explain attachment
instructions to the operator. Visits were also
made to workstations continuously during
testing to make observations and talk to
operators about the results. The result from the
test is displayed in Table 3. In both experiments,
the motor component with the RFID
transponder attached was sent through the
washer on a standard washer pallet. After the
washing operation the transponders were
inspected and if they still were securely fixed to
the motor component they were counted as
eligible and as a passed test.
41
CASE STUDY MllP: RFID SYSTEM DESIGN
42
CASE STUDY MllP: RFID SYSTEM DESIGN
Figure 22: VSD for the implementation of RFID. Red boxes symbolize RFID (Source: compiled by authors).
43
CASE STUDY MllP: RFID SYSTEM DESIGN
containing the transponder towards a RFID transponder against the antenna. This also
reader. Work instructions to these processes signals the end of washing operations.
have been created and can be seen in Appendix
6. The second flow, however, is automatic and
does not require the active involvement of
operators to function. Logic for how Crosstalk
should interpret the signals is also a result from
the case study that is presented in its concept
form in Appendix 7.
The first workstation is equipped with a
computer and equipment for writing the
information for the motor to the transponder
through a RFID-writer.
The first antenna is located at a workstation in
the kitting area, seen in Figure 24. This means
that the transponder will have to follow the
motor in a plastic folder from this station.
Operators manually scan the transponder when
kitting is started by holding up the transponder
against an antenna.
Figure 25: RFID reader installed in the pre-
assembly station (Source: authors’ picture).
The third antenna is located inside the assembly
area over a conveyor belt leading to the testing
area seen in Figure 26. The antenna is attached
to a fixture one meter over the conveyor belt,
facing down on. The scan is automatic when the
motor passes under the antenna. This signals the
end of assembly operations.
44
CASE STUDY MllP: RFID SYSTEM DESIGN
45
CASE STUDY MllP: RFID SYSTEM DESIGN
assembly operations. The antenna reader is a area or maybe even to the last step in the process
mobile reader for manual scanning. This flow for manufacturing operations.
antenna was not implemented during the case
A visual signal of a transponder being read is
study but the hardware was purchased and the
already built into some of the antennas installed
personnel were informed of a future
and the mobile reader. However, the antennas
implementation on that station.
installed at the testing chamber, over the gate to
the accessories station and between the painting
7.5.1 Workshop Results and packing area do not visually display a signal
The workshop held with the operators when successfully reading a transponder. A
highlighted some potential problematic areas suggested improvement on the design would
and potential secondary functions the RFID thus be to add a system for signaling reads into
system could realize. The suggested wishes for the design.
improvement can be described as; The suggested points for receiving a picking list
or a constructional drawing when scanning a
Visual signal when a transponder is
transponder should be more thoroughly
read for security
investigated before considering it a suitable part
Receiving a picking list when scanning of the design. It is believed by the thesis group
transponder that these points would need some kind of
portable display suitable for industrial
Receivnig constructional drawing
environment e.g. a tablet.
when scanning transponder
The point on conveying information on the
Seeing number of motors that has been transponder to the testing software system is
done in one day. something that the thesis group has investigated.
Conveying information on transponder The information gained from this investigation
to testing chambers showed that it was difficult to realize this
suggestion without the direct involvement of the
Abnormalities not obstructing the testing software supplier, Seifo.
RFID system.
Certain exceptions in how a motor passes
The full results from the workshop can be seen through the assembly line was mentioned in the
in Appendix 8. workshop. The impact on the RFID system
installed by the thesis group is that some motors
7.5.2 Suggested Design Improvements would get registered on multiple occasions at
specific antenna read points. The drawback to
The suggested improvements are design choices
this is that the monitoring system cannot
that for different reasons were cut out from the
indicate the reason behind multiple reads. The
final design, but are considered the best solution.
issue was discussed but omitted from the design
The optimal implementation design would be to
mainly because of time delimitations. This is,
achieve automatic registration through the
however, not perceived as a big issue since the
entire RFID system. This would mean that the
last location of the motor will still be shown in
RFID transponder is attached at the first step of
the monitoring system. Should MllP wish to
the process flow for assembly and registered
improve on the design, there is always the
without any effort from an operator. As a result
possibility of adding another point for manual
of the fact that the physical placement of the
registration of exceptions. This could be done
transponder interferes with specific assembly
with a mobile reader. According to the operators,
operations, further investigation of a new
these exceptions pass through roughly the same
placement or transponder type is suggested as an
area.
area for future improvement. This also means
that the attachment of the transponder will have The pick-up area for the paint shop where RFID
to be moved from the assembly to the kitting antennas already existed and used for the paint
46
CASE STUDY MllP: RFID SYSTEM DESIGN
47
CASE STUDY MllP: RFID SYSTEM DESIGN
Figure 31: Concept for real-time monitor design (Source: Compiled by authors).
48
CASE STUDY MllP: RFID SYSTEM DESIGN
7.7 Risk Assessment instructions and validate them with the users,
other countermeasures were seen as valid
A risk assessment for the implementation not
through a thorough mapping of the operators
working properly was compiled. This was used
processes. Countermeasures to (2) unregistered
to increase awareness of potential risks which
transponders, were considered as performing
were taken into consideration during the
tests on the tag in live environment and having
execution of the implementation. Identified
consistent contact with the software supplier
major risks for the implementation not working
and CoC, a transponder with sample
properly can be seen in Figure 32 and were
information from a motor was also sent to CoC
specified as; (1) Effects on external
for inspection. Countermeasures to (3) incorrect
environment from the RFID system, where the
measurements, were similar to (2) unregistered
system could potentially affect other work
transponders, with the addition of having
routines or intrude on equipment usage, (2)
validated measuring points with MOE at several
unregistered transponders, related to hardware
occasions. Countermeasures to (4) Software-
and software functionality or installation but
related issues, were seen as having consistent
also human interaction, (3) incorrect
contact with nofilis and CoC before and during
measurements, via the RFID design or unknown
implementation and by following the GS1
variations or errors in data, (4) Software-related
standards for setting up the system logic.
issues, such as conflicts between systems, and
Countermeasures to (5) personnel-related issues,
lastly (5) personnel-related issues, such as
were seen as taken into consideration through a
resistance to change, unclear instructions of use,
constant contact with the operators and
or unknown sub-optimization of work routines
communicating a clear statement of the
among personnel.
objectives and delimitations of the
Countermeasures to (1) Effects on external implementation, and also through the produced
environment from the RFID system, was work instructions.
considered to be constructing clear work
Figure 32: Ishikawa diagram of assessed risks associated with implementation at MllP (Source: Compiled by
authors).
49
CASE STUDY MllP: RFID SYSTEM DESIGN
50
Case study miip: Implementation
51
CASE STUDY MllP: IMPLEMENTATION
52
CASE STUDY MllP: IMPLEMENTATION
company named Toriro. To make sure group. The data sheets contained general
everything was succeeding according to plan, information and safety details on the hardware.
the installation was followed up almost on a The hardware has also been pre-selected by
daily basis through inspection rounds together Bosch to meet the European standards and
with the contracted craftsman. A slight regulations for human exposure to
drawback on the installation was caused by a electromagnetic fields. Despite this, the
late delivery of connection cables for a specific recommendation of the thesis group is that MllP
group of RFID-readers. This mainly postponed is to carry out a more comprehensive
the testing phase, since everything but the observation of radiation through a specialist
connection to the affected RFID-readers could after everything is installed. To meet this end,
be installed while waiting for the delivery. the thesis group initiated contact with the
responsible person and provided the person with
The physical installations of RFID antennas at
both documentation and contact information to
all locations were first made with temporary
the hardware supplier.
fixtures where quick changes of angle or height
were applicable. Due to the authors’ lacking The installation in the testing chambers was a
practical knowledge on how an installation in an previously untested environment for RFID
industrial environment is carried out, the set up implementation according to the CoC. The
was designed to leave room for adjustments. testing chamber environment had several
After a testing and optimization phase the setup potential reflection surfaces because of all the
was fixed and finalized. At the testing chamber, metallic equipment. These reflections can both
an RFID-reader was installed adjacent to the disturb and amplify the RFID-antennas read
antenna needing the connection, with the design signal. As a result, the tuning in this area was
of being available for further installation of an more demanding and was in need of more
additional set of antennas. testing than the other stations. As a result, the
installation was made in only one of the two
After the physical installation of RFID hardware
testing chambers to make sure that the solution
was completed, each setup was connected to the
was working satisfactorily before implementing
local network system. The first step in this setup
it in both testing chambers. To be able to adjust
was to order IP-addresses via the IT support
the antenna placement and direction, a specific
department at MllP and assign an IP-address to
lockable multilinked fastening was attached to
each location with installed hardware. After this
the antennas inside the testing chamber. This
connection to the network was established, the
gave more room for tweaking and optimization
thesis group could connect to the software of the
than in the other installations.
RFID readers for setup and tweaking via the
provided IP-addresses. The bundled software A handheld RFID reader was the selected
for the RFID-readers was used to configure solution for the packing area. Since the irregular
power of the antennas to tune in the reading field work situation in the packing, mostly depending
of each antenna. Since the physical environment of different motors being packed and sent for
at each location was different, the settings of stocking through different gates a manual effort
each antenna differed somewhat to achieve to finish the value was chosen. The solution was
good success rate in reads. The configuration formed together with the managers of the
was done explorative, which meant testing packing workers to interfere as little as possible
settings out and modifying until satisfactory with the established working procedures but
read results were reached. was not implemented since hardware had not yet
arrived at the end of the thesis. This was added
During this process, some questions on safety
to the open point list seen in Appendix 9.
aspects were brought up by personnel. The
safety aspects were related to levels of
8.5 Software Design
electromagnetic radiation. Safety was deemed
satisfactory by MllP based on special data sheets The installation of the equipment also meant
obtained through the suppliers by the thesis setting up the software environment to send a
53
CASE STUDY MllP: IMPLEMENTATION
signal to the digital software systems. Since the each location, the thesis group accessed the
information was to be sent over Internet for hardware-embedded software through Internet
presentation in Kibana, the system needed a and provided the antenna with the correct IP-
database to store and retrieve data from, address. The functionality test was then carried
accessible via Internet. To prepare the system out by checking if the RFID transponder was
for future modifications, the system needed to detected when carrying it inside the antenna
be set up according to the GS1 standards and field. Tuning of the hardware was carried out
logic that Bosch follows. The logic handled until the test could produce correct reads of the
concepts such as relaying information on the transponder.
physical position of the hardware i.e. the
A performance test was carried out in the
checkpoint station, the process type the read
Kibana environment to check the repeatability
object was undergoing and if the object was a
of RFID reads. The test was carried out by
work in progress. This logic is presented in
comparing the transponders that had passed
Appendix 7.
each RFID checkpoint with the reads in the
The software design consisted of both system.
configuring Crosstalk, and designing the RFID
and Crosstalk logic described in the previous 8.7 Introduction and Training
chapter. Software design also includes the An introduction of the project at MllP was
design of the dashboard seen in Kibana. presented to related personnel while taking
Software setup, including setup of database, which department each user belonged to into
software logic according to GS1 standards and consideration. Operators and manual workers
setting up the server for the software were conceived as belonging to the level closest
environment, has mostly been handled in to the system. Here a focus was put on how the
collaboration with CoC. Steps handled by the system would affect their working environment
thesis group has included the order of correct and routines. It was considered important to
services via Bosch, external consultants and point to the fact that the system would not be
setting up the logic for the process steps measuring individual workers but instead the
including GS1 standards. motor itself. A great deal of effort was also put
on discussing how the system could increase the
8.6 Testing and Tuning
working conditions for workers. Another
The testing and tuning process was the phase in important topic that was brought up was the
the case study where a validation of the RFID expectations among the workers. Here, the
system was carried out. Results from the testing thesis group clarified what the system could
phase naturally initiated some tuning to increase achieve after this implementation.
the reading results or to alter some design.
Foremen were introduced to a more finalized
Initial testing was carried out to test design version of the design. The thesis group
options. The result from this test is described explained how the real-time monitoring system
under 7.2 Hardware testing. After the could be used to gain more transparency of the
installation of hardware was completed, a entire group of processes and a clarification of
functionality test was carried out to verify that expectations and what the outcome would be
that the equipment was performing correctly. was also the topic on these introductions. The
The test was carried out by the thesis group. In concept on how information would be shown in
the test an RFID transponder was created with Kibana was presented to collect feedback and
information burnt to the transponder for verify if the concept was perceived as
simulation of RFID reads in the system. The reasonable. Departments where the
transponder was then carried to each location for implementation did not directly interfere with
testing together with a laptop with access to the their work received a general introduction of the
internal network where the software embedded project to be kept up to date with the undergoing
in the RFID equipment could be accessed. At changes in the plant. For supervisors and
54
CASE STUDY MllP: IMPLEMENTATION
managers, the introduction was focused on the reporting of operation start and end times to the
monitoring tool and suggestions on how to production system and enterprise system SAP.
proceed in different areas to recoup all possible Before this is done, the system should not be
benefits of the implementation were discussed. considered fully implemented since it only
provides visual data. As a result of fully
The evolution of the system was considered an
implementing the system, manual reporting can
important part of the thesis and was discussed
be switched to automatic reporting, improving
on all introductions. The motive behind this was
working routines for personnel and reducing
partly to show potential improvements but also
time taken for performing the reporting tasks.
to underline that the implementation done by the
As a very important added step the reports in
authors of this thesis should be seen as a first
SAP will be values based on real-time data. This
step in a greater implementation. With this
will give the benefit of providing values closer
motive, the launch of the system was done with
to the actual outcome of start and end times
all the personnel knowing the possible
which will help MllP in their strive for
improvement areas but also the state of the
shortening lead times. The ultimate outcome of
system at the leave of the thesis group.
this is of course gaining an edge on the
The personnel handling the operation of writing competition by providing customers with a
the information to the RFID transponder possibly shorter and more transparent lead time.
received training and written instructions. The
A critical point for further work is the
instructions were handed out to the personnel
investigation of why the insulated transponders
and can be seen in Appendix 6. Instructions were
are not showing up in Kibana. This issue could
designed by the thesis group to simplify the
possibly be related to the fact that two numbers
processes to the smallest possible operation.
are written to the transponder which possibly
They were designed with written descriptions of
creates a long string of text that Crosstalk cannot
each operation complemented with pictures
send to Kibana. Crosstalk registers a read but
when applicable. The instructions also included
cannot send the information to Kibana for some
contact information to IT support and other
unknown reason. Since registrations of the
individuals who could assist the personnel in
insulated transponders are still being made in
case of errors or if help was needed.
Crosstalk and in the software for the antennas,
8.8 Continuous Work this solution is most probably related to software
issues which nofilis are owners of. Consultants
The belief throughout the thesis has been that at CoC could possibly help resolve this issue as
continuous improvement would play a major well.
part in creating a system were all possibilities
could be realized. During the work with the Another recommendation for continuous work
design of the RFID system, many areas suitable would be to implement the RFID system for all
for various improvements were identified. Some motor types. The assessment of the thesis group
areas for improvement were also firstly is that full traceability and transparency of the
identified and understood when the installation assembly group of processes cannot be
and implementation was in progress. Because of considered complete until all motor types are
the time and personnel delimitations of the monitored. There are instances where operators
project, the thesis group could not realize all the have to leave work on a CA motor to help in
identified possibilities. However, the identified assembly the other motor types. Since the
potential improvement areas were still noted implemented RFID system does not contain
and discussed with related personnel and are information on the other motors, the monitoring
described in this section as a summary of the system will only show that a stop in production
thesis group’s recommended actions for has occurred and not the reason behind the
continuous work. occurrence. It should be noted that assessment
of the thesis group is still that high levels of
The thesis group perceives the next major step traceability and transparency of the CA motor
as the implementation of the RFID system for
55
CASE STUDY MllP: IMPLEMENTATION
will be attained through the RFID system. an interest in knowing which motors are
inbound to be able to prepare equipment and
One examples of a specific situation that could
procedures. The cost for implementing this
arise in the RFID system is when problems arise
would be low, since cheap monitors can be used,
during manufacturing of the motor. The motor
and the benefit would be that operators could
then returns to the assembly area for restoration
sub-optimize processes to shorten cycle times.
or repair which would not give signals in the live
This would also involve the personnel in the
monitoring system until the motor leaves this
development, increasing the feeling of
area again. However, the person observing the
participation and involvement which may
monitoring system would not know why the
decrease defensive behavior to future
motor was returning to the assembly area. Thus,
improvement projects.
one recommendation would be to add an extra
handheld scanner to the assembly area to scan During the design of the system, a major
these special events as “problems or returned” continuous improvement point identified was
which could create a warning message in the the potential removal of existing paperwork.
monitoring system to supervisors and managers. This could be described as a major “selling point”
for the personnel at the shop floor since the
Another identified point for further work was
subject was brought up several times during
the questions that arose around safety issues
discussions and workshops. The system
among some MOE personnel. Although
implemented at the end of this thesis does not
information on radiation from the equipment
remove any actual paperwork but sets the
was sent to the person in charge, a
framework for reducing it if other systems are
recommendation would be that MllP initiate
interconnected with the RFID system. Scanning
measurements of radiation levels to make sure
the transponder could provide personnel with
that all radiations are on recommended levels.
e.g. instructions for the picking list, receipt card
An identified point for development of the RFID or assemble instructions digitally on a tablet or
system is the addition of functionality in the monitor. A recommendation would thus be that
testing chambers. Here the recommendation is MllP analyses potential areas for reduction of
that MllP investigates how the signal from the paper work. This improvement has the potential
RFID-readers inside the test chambers could to reduce cost and time taken for printing papers.
automatically provide the testing software with
The most critical open points were compiled
data. This would improve the working condition
into a document, seen in Appendix 9. Since the
of the operator by removing the time taken to
system could not be taken into full use before
manually insert data that is stored on the
some of the issues were solved the project was
transponder.
handed over to a new project manager. The
Another identified point for further handover was done orally, but a document with
development is that MllP installs monitors in the status of the open points was used as a
certain stations to show data on incoming confirmation of the information transference.
motors, work in progress, planned work and the
outcome of the work during the day. A previous 8.9 Evaluation
project at MllP identified a need for a tact
As an evaluation of the implementation, a
monitor but did not realize the project because
review of the previously compiled specification
of lacking resources. The visualization system
of requirement was done.
Kibana can be used to display this type of
information. It is possible to create different In regard to (1) Important functionalities, the
dashboards that display different visualizations bullet point Track lead time was considered
if the information needed varies between partially fulfilled since some small technical
stations. Examples of identified stations for this issues were still in effect after leave of the thesis
are the testing area and the packaging area, group. Speakable real-time monitor were
where operators and personnel have expressed considered functional. Reporting signals
matching what is needed for SAP is considered
56
CASE STUDY MllP: IMPLEMENTATION
as needing more investigation since it could not related to the transponder. The transponder is
be evaluated before the rollout of SAP at MllP. technically readable in the environment but not
Increase transparency of assembly flow is sent correctly to Kibana. Placement should
considered fulfilled during testing and will work allow for process start time and end time to be
properly when the technical issues are resolved. acquired is considered fulfilled and validated
with MOE and LOG. The installed hardware in
In (2) Monitor user requirements, Track lead
the production environment should have
time for specific CA motor in real-time is
minimum effect on operator’s workplace and
considered fulfilled when the technical issues
working routines is considered fulfilled since a
are resolved. Monitoring should be intuitive to
change in design was made in collaboration with
use and understand is considered partially
users to achieve this.
fulfilled through the visualizations provided in
the Kibana dashboards but no in-house In (6) Communication, the bullet point RFID
knowledge exist on the software and some signals must go through Crosstalk and RFID
limitations in the software exist. Trustable and signal must be able to connect to subsystems in
accurate data on motor movement through various cases are considered fulfilled since
value stream is considered successful. Crosstalk, which can send information to
several systems simultaneously, is used as
In (3) Manufacturing operator requirements, the
middleware between reader-signal and Kibana.
bullet point Solution should be easier to operate
than today’s process of reporting is considered In (7) Non-functional requirements, The bullet
obtainable if the RFID system is implemented point Hardware placement must be installed
into SAP. Scanning should be intuitive and non- without effects on safety or working
intrusive on the operators other tasks is environment is considered fulfilled since safety
considered partly fulfilled, since some manual issues have been relayed to responsible parties
operations linked to the system exist while other and taken into account in the hardware
stations are automated. Operators should be selection. Hardware should be chosen in
involved in the development of the solution is accordance with Bosch recommendations has
considered fulfilled because through the been fulfilled through the hardware selection
working method of involving the user in the done in collaboration with CoC.
design process. Reduction of papers attached to
the goods is not fulfilled but recommendations
on further work to achieve this are presented in
this thesis. Reduction of delays and manual
errors in reporting is not considered fulfilled
since reporting to SAP is not yet implemented.
Operators should receive clear instructions on
RFID system and its use is considered fulfilled
since work instructions have been produced and
presented to personnel.
In (4) SAP requirements, the bullet point
Reading point for RFID in workshop should
match reporting points in SAP and Information
from RFID solution should be in SAP
compatible format is believed to be fulfilled but
needs validation with an SAP expert.
In (5) Antenna mounting requirements, the
bullet point Transponders should be fully
readable in the shop floor environment needs
further investigation on the technical issues
57
CASE STUDY MllP: IMPLEMENTATION
58
9 FINDINGS AND
INSIGHTS
59
FINDINGS AND INSIGHTS
60
FINDINGS AND INSIGHTS
61
FINDINGS AND INSIGHTS
The authors of this thesis consider these steps, thesis project was assigned functions connected
also seen in Figure 33, as necessary in an to e.g. data and finance but the assigned people
implementation of RFID. did not get enough resources, i.e. time to assist
the project. This lead to a situation where the
thesis group had to solve problems attached to
these functions, to keep the project moving
forward. This could be considered as taking
resources from the thesis group and may have
delayed some work. A suggestion from this
experience is thus that RFID implementation
projects on this scale should consist of cross-
functional teams with personnel owning the
processes affected, personnel handling issues on
the related performance metrics, hardware and
software experts, owners of network
infrastructure at the plant, craftsmen handling
installation of hardware, and project
management to ensure the completion of the
implementation. The roles of all individuals
should also be clearly defined as to not create
any confusion or discussion of who does what.
By creating a more cross-functional team in the
future for these kinds of projects, a much more
efficient work flow and more thoroughly
reviewed results could be achieved. It is also
possible that a cross-functional team could
come up with a more effective solution.
A clear objective of why the implementation is
being made is crucial for a good implementation.
As described earlier in this thesis, the aim and
scope should be realistic and also clearly
communicated to all affected personnel to avoid
false expectations. This is also supported by
Ting et al. (2013).
An implementation takes a lot of time in
consideration. According to the amount of
resources available for this thesis some
simplifications had to be made to finish the
implementation in time. Thus, the amount of
time given to the project was not enough for a
Figure 33: Necessary steps for an implementation complete implementation. In addition to this it
of RFID according to the authors of this thesis must be considered that CoC for RFID had a lot
(Source: compiled by authors.) of experience on equipment and previous
implementations which helped the project. An
In the case study it became very clear that implementation of RFID without this expertise
several different areas of expertise were group would mean that additional time would
required to achieve a good implementation. This have to be added for mapping out relevant
was also supported by the findings of Ting et al. hardware and software solutions. The exact
(2013). The project team for the case study amount of time needed to implement RFID is
mainly consisted of the thesis group. The master
62
FINDINGS AND INSIGHTS
hard to specify for a recommendation since an The case study showed that a lot of possible
implementation at another plant faces different features for the implementation outside the
challenges. The experience gained from this scope of the initial design were discovered.
case study shows that the timetable was not Especially possible ways of extending the use of
enough to achieve full implementation in a team the equipment for the operators in different
consisting of two full time student working functions.
1600 hours on both the case study and the thesis,
a CoC consultant working on the project parallel 9.2.1 Risk Assessment and Outcome
with other projects, the installation craftsman
working approximately 40 hours with Some of assessed risks related to the
installation, setup of network infrastructure implementation were realized. For example the
taking approximately 4 hours, and consultants at risk (1) Effects on external environment from the
nofilis handling software related issues working RFID system, became real as one of the tools
approximately 12 hours. This shows the used in assembly could not be used when the
importance of thoroughly planning, allocating transponder was attached to the motor. This was
and approximating the time needed to complete however circumvented with the system design.
an implementation of RFID. Consideration The risk (4) Software-related issues, became
should be taken to the complexity of an RFID real. All transponders could be read by the
implementation and all related functions in the antennas and readers but for some unknown
project team handling the implementation. reason, Crosstalk was not able to send this signal
to Kibana.
The empirical findings also showed that the
mapping of processes needs to be correct and
thorough. In this case study, wrong measuring 9.2.2 Real-time Monitoring
points would of course have shown incorrect Through the RFID implementation,
cycle and waiting times, ultimately leading to performance metrics are measured in real-time.
incorrect performance metrics. A success factor This gives the benefits of acquiring data that is
to the thesis group here was involving LOG in up to date, which ultimately may aid
this process to understand their viewpoint on management in decision making as stated by
what needed to be measured. Nevertheless, Chen et al. (2012). The project for reducing lead
when mapping the processes, an open mind is time for the CA motor is an example where MllP
still important to identify possibilities of making has shown a great interest in reducing lead time.
smart design choices. For instance, in this case LOG has stated an interest in acquiring more up
study two processes where initially considered to date time values for cycle times and waiting
separate but further investigation showed that times which a real-time monitoring system like
they could be considered as a united process. Kibana can help sustain. Liukkonen (2015) and
This is something LOG also agreed on. Abdullah et al. (2015) also support using
Performing a thorough investigation of visualization tools to show figures like targets,
processes should also be done to identify differences and efficiency. Performance metris,
potential areas where an implementation could such as productivity, becomes more speaking
disturb working routines, as the case study at when the numbers are closer to the actual
MllP showed. outcome instead of being an approximation
A lot of resistance to change was discovered (Bellgran & Säfsten, 2005). Calculating more
among operators in the workshop. When accurate productivity factors are thus an aspect
holding workshops to and talking to operators that can be gained from the implementation
some negative feelings and anxiety towards the made in the case study. In the future, the data
changes were discovered. These were perceived acquired from the RFID system will have to be
by the thesis group as being the result of earlier implemented into an enterprise system like SAP
implementations, where the operators were not to gain the full benefits of analysis and follow-
involved in the change process. up of lead times.
63
FINDINGS AND INSIGHTS
The management model used at Bosch Rexroth, 9.3.2 RFID as the Chosen Technology
BPS, is built on the principles of Lean. Lean
focuses on reducing wastes and inefficiencies in RFID was selected as the technology for
organizations but to be able to do this the implementation before the start of the thesis.
organization must also be able to identify these RFID can be seen as one possible automated
issues (Hines & Rich, 1997; Näslund, 2008). identification technology among others that
Transparency can thus be regarded as an could be used for tracking.
important factor in achieving Lean or BPS
One of the major downsides with RFID, stated
(Näslund; Ting et al., 2013). More specifically,
by Ting et al. (2013), is the costs, so the benefit
wastes such as unnecessary waiting times or
of selecting RFID instead of cheaper options
excess inventory could be approached with
like i.e. barcode needs to be addressed. In a
information gained through the RFID solution
system using RFID, clear sight to the object
in internal logistics (Hines & Rich; Liukkonen,
being tracked is not needed (Chen et al., 2012).
2015). A better understanding on cycle times
This aspect can be used in the industrial
and in the longer run more ways to increase
environment in e.g. gates as to not disturb
profits are improvements that could be achieved
working routines and maintain an optimal read
(Liukkonen; Ting et al.).
rate. RFID also makes it possible to detect a
JIT is already used through Kanban cards for large amount of products at the same time
material ordering at MllP. RFID in conjunction (Castro Adaujo Filho, Travassos & Figueriedo,
with a real-time monitoring system can help 2011). This aspect is not utilized to a large
visually conveying the status of Kanban cards extent in the RFID implementation at MllP.
for operators (Abdullah et al., 2015; Kumar & However, the implementation utilizes this
Panneerselvam, 2007). Through this, an functionality to a small degree through
organization can follow a material or the simultaneous reads of two motors passing under
physical movement of a product in the factory the gate antennas. Another important reason to
through a digital platform (Abdullah et al.; Chen select RFID over other automated id solutions is
et al., 2012; Heng, 2014; Johansson & Larsson, the greater accuracy of the technology
2015; Kagerman et al., 2013). It is also possible (McFarlane et al., 2003). A good way of using
to achieve a more modern version of JIT, coined the RFID in a production environment is to
T-JIT, where the principles of pull production is visualize the reads for the operators (Abdullah
applied on other areas. Although this application et al., 2015). It can preferably be used to
is not directly related to RFID, a design of a describe the status of a working station perhaps
complete system where RFID plays the role of together with a status and goal of the production.
digital id for each object, could be linked to
64
10 CONCLUSIONS
The conclusions stand as the culmination of the master thesis and answers the
initially stated research questions. These are the results derived from a
combination of the theoretical and empirical insights gained throughout the
process of work. The conclusions are presented under the corresponding
research question in a table. The table also contains a reference to the section
in this report where the insights to each conclusion is presented.
65
CONCLUSIONS
CONCLUSION SUPPORTED BY
An implementation of RFID should include steps such as;
(1) Defining the scope
(2) Analyzing of the existing system
(3) Mapping of hardware and software
Theoretical insights
(4) System design 9.1.3
(5) Prototype testing
Empirical insights
(6) Installation 9.2
(7) Software design
(8) Testing and tuning
(9) Introduction and training
(10) Continuous work and improvement.
Theoretical insights
9.1.3
Clear objective of the implementation.
Empirical insights
9.2
Theoretical insights
Information of objectives to all stakeholders to avoid 9.1.3
misunderstandings and unrealistic expectations.
Empirical insights
9.2
Theoretical insights
9.1.3
A correct and thorough mapping of the affected processes.
Empirical insights
9.2
User involvement to facilitate a complete implementation. A Theoretical insights
clear responsibility for involving users and communicating 9.1.1 and 9.1.3
objectives and aims of the implementation should also
Empirical insights
be established.
9.2
66
CONCLUSIONS
Theoretical insights
9.1.2
Empirical insights
Increased transparency of the value chain.
9.2
General insights
9.3.1
Theoretical insights
Potential reduction of tedious work tasks like manual 9.1.2
reporting.
Empirical insights
9.2
Theoretical insights
Potential increase in productivity.
9.1.2
Theoretical insights
9.1.2
Real-time information on performance metrics. Has the added
benefit of giving an organization more correct information Empirical insights
for decision-making. 9.2
General insights
9.3.1
67
CONCLUSIONS
CONCLUSION SUPPORTED BY
Theoretical insights
Through a real-time monitoring system, like Kibana, 9.1.2
accessible through the Internet.
Empirical insights
9.2.1
Theoretical insights
By creating the possibility of remote access to the real-time 9.1.2
monitoring system from anywhere in the world.
Empirical insights
9.2.1
Theoretical insights
By creating a digital version of a physical object used in the 9.1.2
industrial environment.
General insights
9.3
Theoretical insights
Through the creation of a cyber-version of the plant and the 9.1.2
processes.
Empirical insights
9.2.1
With increased amounts of data for analysis and decision- Theoretical insights
making. 9.1.2
Theoretical insights
Potential reduction of tedious work tasks like manual 9.1.2
reporting.
Empirical insights
9.2
68
CONCLUSIONS
69
CONCLUSIONS
70
11 DISCUSSION
The results and insights gained from the master thesis are discussed in this
section. Here, a critical review of all the results is compared to the initially
stated objectives and aims. Covered subjects and possible flaws of the
implemented system are explained and considered in relation to the results
achieved.
71
DISCUSSION
considered in terms of how it may affect the end needed for RFID, but this thesis shows that there
result. For an implementation this means that are existing standards being used for the
most processes are more time consuming than technology. The belief of the authors of this
they may appear initially, especially if the thesis is that this can facilitate further
implementation has a strict timetable with no implementation of the RFID system into
room for setbacks. It is the belief of the thesis enterprise systems or other manufacturing
authors that a minor setback in the early execution systems.
processes could have caused problems enough
The results of the case study can in many ways
to jeopardize the entire implementation.
be described as a confirmation on the theoretical
To succeed with an implementation similar to findings on RFID implementation presented in
the case study a deep understanding of the this thesis. The case study further underlines the
affected processes, an expertise of the importance of having resources in terms of
technology used, and knowledge of expertise and time to facilitate the
programming languages to get a system is implementation. The case study has also shown
needed. Furthermore, the right resources have that an early user involvement aids in
to be assigned to the project to succeed. Right identifying areas for improvement but also risk
resources include technical expertise of both factors to a successful implementation that
hardware and software needed in the project, but could not have been discovered only through
also time as a resource dedicated to the different observations.
functions of the project. Another identified
As an addition to presenting how an
critical function is project management. In the
implementation of RFID can be designed, the
case study at MllP this was not clearly defined
case study presented in this master thesis clearly
in the start but the role was gradually established
shows that an implementation of RFID has
as belonging to the thesis group. The project at
several aspects that can help an organization
MllP was on several occasions suffering from
realize i4.0.
the lack of important functions such as clear
management and the lack of technical expertise. 11.4 Reflections
Despite this, the thesis group managed to solve
tasks initially assigned to other parties involved The theoretical findings suggest that the
in the project. Examples are software-related expenses of RFID implementation are one of the
tasks, such as database structuring and software main causes of concern. According to the
logic but also following up on the expenses of manager of i4.0 projects at MllP (Personal
the project. These insights have shown that this communication, 2016-02-01), the aim is to have
type of implementation requires a larger a return of interest within two years for projects
operational team to succeed. A positive aspect like this. The benefits of the implementation are
of the case study was the expertise and mostly calculated on estimated efficiency
knowledge of the CoC departments for RFID progress in the production. In this case study the
and event monitoring. Their experience on calculations were not considered. Furthermore,
previous RFID implementations and event the thesis group cannot point out definite
monitoring has been a crucial factor to the savings in the production realized through this
success of the implementation. implementation, but there are several points
recommended for continuous improvements
11.3 Positioning the Result that might increase efficiency and generate
savings. This is also one of the main reasons
Implementation of RFID is in many aspects
why the continuous work is seen as important.
similar to implementations in industrial
If the return of interest is considered important
environments in general. The case study has
for this case, the thesis group suggests that it
touched safety issues and standards on RFID
should be clearly specified in the project
hardware and software logic. The theoretical
objectives and aims. A suggestion is that key
findings indicated that more standards were
73
DISCUSSION
75
AnnAAAAWgaagtag
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79
Appendix 1
PROJECT PLAN
THEORETICAL FRAMEWORK
PROCESS MAPPING
SITUATIONAL ANALYSIS
DESIGN PHASE
Workstation design
Software design
IMPLEMENTATION
Physical Installation
Software setup
Testing phase
Training
Live test
EVALUATION
ANALYSIS
Opposition 1
Opposition 2
DOCUMENTATION
PRESENTATION PREPARATIONS
Appendix 2
2016-02-29 Phone meeting John Reimers, CoC (1) RFID hardware 1,5 h
2016-03-02 Meeting Cross talk equipment 1h
IT department (2)
Software environment
2016-03-02 Observation/ MOE(1) , LOG (1) 0,5 h
meeting Carolina Sondell Concept for RFID in VSM
Sara Edholm
2016-03-11 Phone meeting CoC (1) Implementation design 1,5 h
2016-04-18 Meeting IT department (2) Network setup 1h
2016-04-19 Presentation MOE (12), foremen Project information, feedback 1h
2016-04-21 Presentation MOE (8), managers Project information, feedback 1h
2016-05-04 Meeting MOE (2), paint shop Discussion on implementation 1h
managers in paint shop
2016-05-11 Handover Anders Palm Handover of results and CIP 2h
2016-05-12 Skype meeting Nofilis (1), CoC (1) Setup of system in Crosstalk 8h
2016-05-18 Demonstration Sponsor, MOE (1), Demonstration of project 0,5 h
LOG (1), Visitors (6) results and Kibana
Appendix 3 (1/2)
Inledning:
Exjobb från jan-maj, från LTU
Vi gör en studie om hur man kan använda RFID, hur vi kan hjälpa operatörer, arbetsledning, säljare,
företransponderet i stort för att öka konkurrenskraft.
Hägglunds motor är bästa på marknaden
Kunderna efterfrågar snabba leveranser – 2w ledtider
För att kunna säkerställa leveranserna vill man kunna följa och säkerställa att man klarar leveranstiderna.
Det är en del i projektet, systemet kommer bara följa motorerna genom processerna inte mäta
processerna.
Så det vi nu vill veta av er är vad vi kan dra mer för nytta av detta.
Initiera diskussion
Något om vad man kan använda det till…
Busskort, träningskort
Identifiering av djur
Lidingöloppet RFID-märke i skon så kompisar kan följa löpare i realtid.
Har ni några erfarenheter av RFID eller liknande användning?
Gruppdiskussion:
Kan vi som är här inne få ut av det här?
Vad kan ni få för nytta av det här?
Vad skulle ni vilja veta av vad som händer i övriga fabriken?
Hur skulle ni vilja arbeta med transpondergning och avrapportering
Att anteckna:
Hur många och vilka avdelningar var där:
Avdelning:____________ Antal:__________
Avdelning:____________ Antal:__________
Avdelning:____________ Antal:__________
Avdelning:____________ Antal:__________
Avdelning:____________ Antal:__________
Figure 3: Nordic ID Morphic Cross Dipole / UHF RFID reader (Source: Bosch Intranet).
Kathrein UHF RFID Wide Range antennas 70°
Gate reader.
Wide Range RFID antenna for reading of RFID transponders.
Read range: up to 12 meters*.
Dimension (without brackets): 271 x 271 x 43 mm.
Needs additional reader, i.e. RRU4.
Figure 4: Kathrein UHF RFID Wide Range antenna (Source: Bosch Intranet).
A table of the correct format to mark each antenna/checkpoint position can be seen below. 1000 unique
numbers have been given to the Mellansel plant, indicated by XXX in the table (choosing an nr between
0-999). A string of numbers also point at the business sector Drive and control which Mellansel is a part
of.
Indicator
Company prefix (CP) Business sector Location nr
digit
4 0 4 8 1 1 8 8 1 0 0 0 0 3 0 0 0 0 0 0 0 0 0 X X X
Global Trade Item Number (GTIN) can be used by a company to uniquely identify all of its trade
items. (S)GTIN is a GTIN with a serial number added in the end of the key. The Hägglunds CA motors
are examples of items where a serial number exists.
Appendix 6 (1/2)