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Using RFID Technology for Rapid Changeover

In today’s tight economy, marked by high inflation and supply chain issues, the need to enhance product flexibility has become increasingly important. Most manufacturing lines these days are set up to run multiple work orders of the same product type based on specific requirements. The goods produced at the manufacturer line are still the same, but the package size can change. The raw materials that start the process might be the same, but other component parts and tools on the machine that help with the different packaging sizes must be replaced. The process of converting one product line or machine to another is known as changeover. This blog explores how Radio Frequency Identification (RFID) technology can revolutionize changeover by eliminating manual verification and adjustments.

Challenges of changeovers

Changeover can involve swapping out parts, tools, or molds specific to each product along with setting up specific parameters on the PLC controller for that product run. This requires personnel to make sure all the required parts are exchanged out correctly and the new settings are correctly entered into the controller. Afterward, it is necessary to verify that everything is correct before full production starts again with the new work order. Any incorrect setting part replacement can result in wasted product and troubleshooting. During this changeover period, no products are being produced since the machine/line is being set up for the new work order. Therefore, it makes sense to try and reduce this time as much as possible to maximize production efficiency and reduce produce waste.

Role of RFID technology in streamlining changeovers

Using Radio Frequency Identification (RFID) technology can significantly help changeover in the manufacturing process by preventing errors, and ensuring correct component loading and accurate parameter settings. RFID tags can be attached to different parts requiring replacement for various packaging sizes and to store all the information needed for the production run, including product-specific settings and parameters that need to go back to the PLC controller.

In the figure below, three RFID tags are attached to different parts needed to run the production Variant A of a product. All three tags are programmed for use with Variant A along with any required settings for the controller. For a different product size, the parts that needed to be swapped out would have a unique RFID tag on them – Variant B, for example. Before the controller starts a new production run, a RFID antenna can quickly scan the RFID tags to verify that all three Variant A parts are on the machine. The RFID antenna can quickly tell if a part was missing, or if Variant B was loaded by mistake. This can be tied back to a signal on the controller so that it does not run. The RFID antenna can also read the product-specific settings on the RFID tags and send those parameters to the controller as well, eliminating the need to manually enter the settings in the controller.

RFID helps by taking out the manual verification and adjustments needed by the operator. With careful planning and implementation, RFID technology can help reduce downtime, increase productivity, and improve operational efficiency.

Click here to learn about guided changeover solutions, including step-by-step instructions to improve OEE.

IO-Link Changeover: ID Without RFID – Hub ID

When looking at flexible manufacturing, what first comes to mind are the challenges of handling product changeovers. It is more and more common for manufacturers to produce multiple products on the same production line, as well as to perform multiple operations in the same space.

Accomplishing this and making these machines more flexible requires changing machine parts to allow for different stages in the production cycle. These interchangeable parts are all throughout a plant: die changes, tooling changes, fixture changes, end-of-arm tooling, and more.

When swapping out these interchangeable parts it is crucial you can identify what tooling is in place and ensure that it is correct.

ID without RFID

When it comes to identifying assets in manufacturing today, typically the first option companies consider is Radio-Frequency Identification (RFID). Understandably so, as this is a great solution, especially when tooling does not need an electrical connection. It also allows additional information beyond just identification to be read and written on the tag on the asset.

It is more and more common in changeover applications for tooling, fixtures, dies, or end-of-arm tooling to require some sort of electrical connection for power, communication, I/O, etc. If this is the case, using RFID may be redundant, depending on the overall application. Let’s consider identifying these changeable parts without incurring additional costs such as RFID or barcode readers.

Hub ID with IO-Link

In changeover applications that use IO-Link, the most common devices used on the physical tooling are IO-Link hubs. IO-Link system architectures are very customizable, allowing great flexibility to different varieties of tooling when changeover is needed. Using a single IO-Link port on an IO-Link master block, a standard prox cable, and hub(s), there is the capability of up to:

- 30 Digital Inputs/Outputs or
- 14 Digital Inputs/Outputs and Valve Manifold Control or
- 8 Digital Inputs/Outputs and 4 Analog Voltage/Current Signals or
- 8 Analog Input Signals (Voltage/Current, Pt Sensor, and Thermocouple)

When using a setup like this, an IO-Link 1.1 hub (or any IO-Link 1.1 device) can store unique identification data. This is done via the Serial Number Parameter and/or Application Specific Tag Parameter. They act as a 16- or 32-byte memory location for customizable alphanumeric information. This allows for tooling to have any name stored within that memory location. For example, Fixture 44, Die 12, Tool 78, EOAT 123, etc. Once there is a connection, the controller can request the identification data from the tool to ensure it is using the correct tool for the upcoming process.

By using IO-Link, there are a plethora of options for changeover tooling design, regardless of various I/O requirements. Also, you can identify your tooling without adding RFID or any other redundant hardware. Even so, in the growing world of Industry 4.0 and the Industrial Internet of Things, is this enough information to be getting from your tooling?

In addition to the diagnostics and parameter setting benefits of IO-Link, there are now hub options with condition monitoring capabilities. These allow for even more information from your tooling and fixtures like:

- Vibration detection
- Internal temperature monitoring
- Voltage and current monitoring
- Operating hours counter

Flexible manufacturing is no doubt a challenge and there are many more things to consider for die, tooling and fixture changes, and end-of-arm tooling outside of just ID. Thankfully, there are many solutions within the IO-Link toolbox.

For your next changeover, I recommend checking out Non-Contact Inductive Couplers Provide Wiring Advantages, Added Flexibility and Cost Savings Over Industrial Multi-Pin Connectors for a great solution for non-contact connectivity that can work directly with Hub ID.

Using Guided Format Change to Improve Changeover and Productivity

Long before Covid, we were seeing an increase in the number of packaging SKUs. In 2019, Packaging Digest reported an estimated 42% increase in SKUs in the food and beverage industry.

Since Covid, there has been a further explosion of new packaging sizes, especially in the food and beverage marketplace. Food manufacturers have gotten very creative. Instead of raising prices due to the higher costs of goods, for example, they can reduce the size of product packages while keeping the consumer prices the same.

Many of today’s production machines are not equipped to changeover as quickly and as accurately to meet the demand of the marketplace. Manufacturers now face the challenge of “semi-automating” their existing machines, as opposed to procuring new machines or adding expensive motors to existing machines. One solution is to digitalize change points on existing machines.

Companies are looking to reduce the amount of time and the mistakes that occur when doing product changeovers. Allowing for operator guidance and position measurement can reduce your time and enhance your accuracy of those changeover events. Measurements are then tied to the recipe and the operator becomes the prime mover.

Guided Format Change

There are lots of technologies out there for helping with guided format change, such as automated position measurement, machine position, distance measurement, linear measurement, and digitalized rotary encoders.

As you are likely quite aware, there are often scales, marks, etc., written onto machines that don’t provide the greatest degree of accuracy. Introducing digitalized position and distance sensing can help you reduce time and limit errors during changeovers.

Change Part Identification

The other side of changeover is change part identification. Quite often during this process parts on the machine must be exchanged. Using the wrong change part can result in mistakes, waste, and delays, and can even damage existing machines.

Technologies, such as RFID, can help ensure the correct change part is chosen and added to the machine. During a recipe change, the operator can then validate that all the correct parts are installed before the startup of the next product run.

Guided format change is a cost-effective way to reduce changeover time and increase productivity either by retrofitting your existing machines or even new machines.

The Benefits of Guided Changeover in Packaging

Today’s consumer packaged goods (CPG) market is driving the need for greater agility and flexibility in packaging machinery. Shorter, more customized runs create more frequent machine changeover. Consequently, reducing planned and unplanned downtime at changeover is one of the key challenges CPG companies are working to improve.

Many packaging machine builders are now providing fully automated changeover, where motors move pieces into the correct position upon recipe change. This has proven to be a winning solution, however, not every application can accommodate motors, especially those on older machines.

Guided changeover represents an opportunity to modify or retrofit existing equipment to improve agility and flexibility on older machines that are not yet ready to be replaced.

An affordable intermediate step between fully manual and fully automated changeover:

A measurement sensor can be added to provide position feedback on parts that require repositioning for changeover. By using indicator lights, counters or displays at the point of use, the operator is provided with visual guidance to reposition the moving part. Only once all parts are in the correct position can the machine start up and run.

By utilizing this concept, CPG companies can realize several key benefits:

Reduced planned downtime: Adding guidance reduces the amount of time it takes to move parts into the correct position.
Reduced unplanned downtime: Providing operator guidance minimizes mistakes, avoiding jams and other problems caused by misalignment.
Reduced waste: Operators can “dial in” moving parts quickly and precisely. This allows the machine to be fully operational sooner, minimizing runoff and scrap.
Improved operator training: Providing operator guidance helps CPG companies deal with inevitable workforce attrition. New operators can be quickly trained on changeover procedures.

Selecting the correct sensor

A variety of sensor technologies can be used to create guide changeover; it’s really a matter of fit, form and function. Common technologies used in changeover position applications include linear positioning transducers and encoders. Other devices like inductive and photoelectric distance sensors can be used with some creativity to solve challenging applications.

Available mounting space and environmental conditions should be taken into consideration when selecting the correct device. Sensors with enhanced IP ratings are available for harsh environmental conditions and washdown.

Analog devices are commonly used to retrofit machines with older PLCs, while IO-Link can be used in place of analog for a fully digital solution, enabling bi-directional communication between the sensor and controller for condition monitoring, automatic device replacement and parameter changes.