Mondi Inncoat GmbH
By implementing an RFID tracking system, challenges in production are overcome, efficiency is increased and transparency in tool management is improved.
Who is
Mondi?
Mondi?
Mondi is a global leader in the packaging and paper industry. The company develops innovative and sustainable packaging solutions and high-quality paper products for a wide range of industries, including consumer goods, industrial, printing and more. With a strong focus on sustainability and innovation, Mondi aims to reduce resource consumption and make a positive contribution to the environment through intelligent packaging solutions. Mondi employs around 22,000 people in more than 100 production sites worldwide.
Business Challenge
Challenge:
- High reject rate due to incorrect use of very similar or minimally different tools
- Time lost when searching for tools due to lack of transparency
- Tool mileage and wear are not recorded, making efficient maintenance more difficult
- Need for robust technology that works reliably even in demanding environments
Goals:
- Minimize production downtime and waste
- Improving transparency in the production process
- Scalability of the system to other locations and applications
Solution
- Process analysis and detailed examination of the production processes including the prevailing environment
- Implementation of a two-stage proof of concept (technological clarification and on-site integration)
- Technology selection and testing of the use of RFID tags under difficult conditions (alkaline environment, hazardous area)
- Concept for attaching RFID tags to tools, development of the Omlox standard for future expansion, integration of RFID tags in the production system and MES
- Implementation of the RFID tracking system for the unique identification of tools (e.g. printing rollers)
- Equipping tools with RFID tags, installing RFID readers at five production stations and at washing and storage stations
- Integration into existing systems (Siemens MES and PI system) via OPC UA interfaces
Services
- Consulting and planning of RFID integration.
- Implementation of a proof of concept (PoC) for technological clarification and integration.
- Development of prototypes for attaching the RFID tags.
- Technical tests to ensure signal quality, durability and mounting methods.
- on-site installation and commissioning of the system.
Technologies
- UHF RFID tags and RFID readers.
- OMLOX standard for possible extensions.
- Siemens MES, Osisoft PI system.
- OPC UA interfaces for data communication.
- Industrial PC for controlling the RFID readers.
Methods
- Implementation of a proof of concept in two phases: Technological clarification and on-site integration.
- Iterative testing of fastening methods (gluing, screwing, integration in sleeves or rollers).
- Simulation and optimization of RFID positioning to maximize read range and signal quality.
Value
- Reduction of production downtimes through early detection of incorrect tool assignments.
- Enabling traceability and avoiding incorrect material deliveries and the associated costs.
- Enabling predictive maintenance.
- Scalable solution for additional locations and production lines.
- Potential to expand the system (e.g. UWB for warehouse logistics).
