"Filip Morris" organized a production control system on the basis of RFID technologies

On October 11, 2016 the RST-Invent company announced signing of the contract on creation of a control system and the movement of raw materials on production lines of Filip Morris Izhora factory in the Leningrad Region, and in 2018 the project results were summed up.

"Filip Morris" organized a production control system on the basis of RFID technologies

Project Tasks

According to the technical project of the project of RST-Invent it was necessary to develop, make and implement a number of RFID solutions which would help to control compliance of the components given to the assembly line to the made products sign in real time. Participation of the person had to be minimized by technology in a production process. The full integration of the created hardware and software system with a management system for production process of the customer was assumed.

Project Progress

Within the project the RST-Invent company implemented a number of the customized RFID solutions to assembly lines of the customer. They allowed to monitor in the online mode compliance of components and excluded influence of a human factor on quality of the tobacco products released by the enterprise. Also the full integration of the developed solution with the MES system of the client was performed.

Principle of system operation

For control of correctness of giving of semi-finished products of cigarette filters on production lines in the system developed by RST-Invent the RFID tags attached to a plastic or cardboard tray are used.

RFID tags are attached to a tray with semi-finished products of filters

A system assigns the code for each tray when filling with its semi-finished products of filters. For this purpose all production lines which are releasing semi-finished products are equipped with the RFID modules making automatic recording of the identifier in memory of a RFID tag of a tray on the basis of the task received from MES.

The identifier not only unambiguously defines semi-finished product type in a tray, but also comprises the code of specific type of future cigarette filter.

Control of correctness of giving of semi-finished products is exercised on section of receipt of trays of ready cigarette filters on production lines. The RFID readers installed on lines compare the code of the filter in a RFID tag to the code received from a MES system.

The correctness of giving of semi-finished products is checked on section of receipt of the filled trays for production lines

In case of coincidence of codes, semi-finished products go to processing. In case of an error, there is an automatic stop of the line, loading of semi-finished products is not made, and the operator receives a warning in the form of a light signal.

In need of repacking of a semi-finished product from a cardboard tray in plastic, a system automatically transfers all identification information to a RFID tag of a plastic tray.

The unique identifier is appropriated to each RFID tag in the database of a system. When loading a tray semi-finished products of filters, in a RFID tag the corresponding code of the filter registers. At the time of giving of semi-finished products on a production line reading the code of the filter is executed of memory of a RFID tag.

The code of the filter from a MES system is transferred to the database and then sent on all RFID readers of production lines. Information on loading or unloading from a tray of a specific semi-finished product on a production line remains in base from which, further, it is transferred to the MES system of the customer.

The used solutions

Especially for the Filip Morris project a special series of RFID tags TwinTag with the increased amount of memory executed in the form of a sticker was developed and made. The tag is unified for marking of two types of trays: cardboard and plastic. The possibility of installation of different models of UHF chips is provided in it. The RFID tag is designed taking into account requirements of steady registration of objects in the different planes (3D - a format), and its characteristics provide steady reading on production lines.

Especially for the project a special series of RFID tags with the increased amount of memory is developed

Besides, the RFID reader RST-MAR equipped with antennas with unique design was developed. Antennas are equipped with magnetic fastening and sensors for control of existence of a tray. Installation of antennas is performed without making changes in construction of production lines.

RFID reader RST-MAR

Project Results

The constructed RFID system helped to automate control of technology processes by production of cigarette products, increased transparency and efficiency in process control. Thereby a system minimized involvement of the person in quality control of a product and, as a result, allowed to prevent the errors connected with use of the raw materials which are not intended for production of certain products.

Projects in the field of industrial automation are of special value for us. First, implementation of the production RFID solution are a guarantee of continuation of cooperation, at least at the level of deliveries of supplies, RFID tags, not to mention service, upgrade, expansion of a system and so on. Secondly, in such tasks the company can not only brightly show the saved-up scientific and technical and potential production, but also is qualitatively motivated on development and optimization of the competences, sometimes in areas, absolutely non-standard for the RFID market. For example, for fulfillment of requirements "Filip Morris Izhora" our engineers studied magnetic materials and alloys, - Alexander Grebennik, the CEO of RST-Invent commented.