【HaiChuan Discussion】In which areas of chemical production has QR code management been implemented?

Solid asset management (or: equipment management) uses QR codes.

Of course, there are also computers, with QR codes attached to the back of each one.

According to Sinopec News Network, on the morning of December 11, the resin product invoicing office at Zhenhai Refining & Chemical’s on-site office, which is usually crowded and bustling, was eerily empty with no one around. On this day, it’s not that freight forwarders stopped coming to collect the goods; rather, the process for collecting them was changed to allow forwarders to handle it online on their own. Physical IC cards were eliminated, and shipping was carried out using QR codes. 　　This day is a milestone-like, special day for Zhenhai Refining & Chemical, the Zhenhai Refining & Chemical on-site office for chemical sales, and the carriers. 　　After more than half a year of discussions and coordination between the Zhenhai Refining & Chemicals on-site office and various departments at the company, it was possible to implement a process for loading goods by scanning QR codes using resin products; the IC cards that have been in use for over 7 years are now entering the countdown phase before being phased out. This means that the shipping process for resin products eliminates the cumbersome paper-based procedures; carriers no longer need to make multiple trips to the factory to collect paper documents or handle IC cards. They can view the orders that need to be delivered through the reservation system, and independently determine the quantity of goods to be picked up, conduct batch calculations, and make reservations for vehicles. 　　The successful transition to the pickup system has allowed carriers to save a great deal of time, gain greater autonomy, and coordinate and allocate vehicles more effectively to optimize resource utilization. 　　The ones who benefit the most from this are drivers. With the QR code-based intelligent shipping system, along with the reservation system that has been in use previously, drivers can carry out safety training and exams in the system at any time and from anywhere as long as they have a smartphone. After passing the exams, they simply need to show their ID card to enter the factory ； Previously, drivers had to obtain paper documents and IC cards through the logistics representative before entering the factory; now, they can simply scan the pickup QR code received on their phones to join the queue for loading. On that day, many drivers who had completed the pickup process expressed their gratitude to the system developers who provided technical support on site through the logistics representatives, and were very satisfied with the convenience of the pickup process. The staff responsible for resin products at Zhenhai Refining & Chemical’s on-site office, who are involved in chemical sales, have also benefited from the introduction of intelligent shipping systems; this has eliminated the need to use mechanical IC cards. As a result, repetitive tasks that require little technical skill have been reduced, allowing them to devote more time to providing customized services to customers and to overseeing safety on site. Zhenhai Refining & Chemical can also expect to reduce the number of employees needed for invoicing tasks, thereby achieving greater efficiency. This represents a win-win situation for all parties involved, and it marks a qualitative improvement in the way shipments are handled. 　　With this transformation of the pickup system, Zhenhai Refining & Chemicals keeps up with the trends of the times; through advancements in intelligent information technology, it enables all parties involved in logistics to experience the power and appeal of technology. 　　It is reported that within the next 3 months, the intelligent shipping system at Zhenhai Refining & Chemical will see the development and implementation of functions such as on-site queue numbering and automatic barcode scanning for shipment; as a result, the shipping system will become more intelligent and efficient. In 2019, the system will also be gradually introduced to all chemical products in Zhenhai, putting an end to the era of shipping using IC cards.

I. Tool management: Tool and equipment management includes the procurement of such tools and equipment, their maintenance, tracking of their in and out of stock status, as well as management of their lending and return processes. It also involves replacing ground-based equipment as seasons change, as well as calibrating measuring instruments and managing their lifespan. Traditional tool and equipment management is primarily carried out through computer-based tool management systems, but these systems do not provide functions for borrowing, returning, and recording, which results in a lack of statistics on usage data and hinders the modernization of tool and equipment management. The lending and returning of tools and equipment generally relies on manual recording, which is an outdated method prone to errors; moreover, there is no record of historical data, making it difficult to keep track of things. As per the regulations, when borrowing and returning tools, it is necessary to check each item’s details one by one, including the item number and serial code, etc. If a set of tools is borrowed, every tool must be verified against the list. When only 1 or 2 tools are borrowed, the time required for this process is acceptable; however, for larger tasks or regular inspections where dozens or even hundreds of tools need to be borrowed, the time spent merely on borrowing the tools could exceed 1 hour using this method, or some tools might be forgotten, which severely affects work efficiency and leads to incomplete record-keeping. For tools that are used frequently, their numbers often become blurred and difficult to distinguish, which poses challenges to the process of counting them and is time-consuming and labor-intensive. Therefore, the original recording method is not only inefficient but also prone to incomplete information recording, leading to chaotic tool management. In situations such as tools being borrowed for troubleshooting at other locations, it becomes even more difficult to keep track of them. There have been instances of tools going missing, with serious consequences, and it was impossible to identify the responsible person. II. Advantages of QR codes in the management of tools and equipment Due to the many shortcomings of traditional management methods, barcode technology was also utilized in the modernization of tool and equipment management. However, barcodes are large in size, making it difficult to attach them to tools; they have poor error correction capabilities, and they can be damaged in the working environment at repair sites. Once damaged, they cannot be read, which poses difficulties in management. The emergence of QR codes has helped to overcome these drawbacks. QR codes feature a small size, large information capacity, high security, high reading efficiency, and strong error correction capabilities. They can not only be used to identify items but also to describe their attributes. Additionally, they have advantages such as strong resistance to interference, good adaptability to different usage environments, and low cost of use. QR codes have a small size and high storage density, making them easy to attach to smaller devices and able to cover more devices. Moreover, they can still be read successfully even if 50% of them are damaged, thanks to their error-checking capabilities; thus, they offer advantages in device management.

The advantages of using QR codes in tool and equipment management are as follows: 1. It enables the identification of unique tools. By utilizing QR code technology, a unique QR code can be assigned to each tool, meaning that every tool has its own unique “ID,” which meets the requirements for tool management set by regulations and helps avoid issues such as duplicate numbering and chaotic management. By scanning the tool’s “ID card” with a scanner, its specific details can be identified. 2. Simplify the borrowing process for tool sets: For tools that are frequently used and can be borrowed as a set, or for smaller tools for which it’s difficult to apply QR codes, it is possible to create a single QR code for the entire set. This QR code contains information about all the components of the set; by scanning this code, the entire set of tools can be borrowed, thereby **reducing the time required for borrowing and returning them**. 3. Unified management of tool information: The QR code management system allows for the recording of various details related to tools, such as their numbers, names, status, specifications, models, parameters, instruction manuals, interchangeability, evaluations for equivalent substitution, and storage locations. This makes it easy to retrieve specific information about a tool. It can also send reminders for replacing ground-based equipment as seasons change, provide reminders for calibrating measuring instruments, and keep track of repairs; furthermore, it enables tracking and management of the tool’s lifecycle. 4. Management of tool intake, output, borrowing, and return: All operations related to tools, such as intake, output, transfer, borrowing, and return, can be recorded and processed by scanning the QR code marked on the tools using a QR code scanner. This enables tracking of borrowing, returns, and the status of tools, offering convenience, speed, efficiency, and accuracy. If necessary, a detailed list of the tools taken can also be printed out, which facilitates maintenance workers in counting them on-site. According to incomplete statistics, compared to traditional methods of tracking tool usage, QR code technology can save nearly 80% of the time required; the more tools there are, the greater the time savings, thereby significantly improving the efficiency of tool issuance and return as well as the speed at which tools can be counted. Additionally, the responsibility for storing and using tools can be assigned to specific individuals, ensuring that borrowing and returning of tools are traceable. Loan and return management is carried out through QR code scanning, which allows for clear recording of the person who borrowed the item, the person who returned it, and the person who performed the operation. In the event that a tool is lost or damaged, it is possible to quickly identify the responsible party, which helps to improve the maintenance and management of tools as well as their lifespan management. 5. Avoid human errors: By identifying the QR code, which represents the tool’s unique identity information, it is possible to reduce human errors when returning tools. The traditional manual registration method often leads to carelessness, resulting in tools being returned incorrectly or not being checked properly; this can cause tools to be left at the work site or even on the plane, leading to unnecessary time-consuming and troublesome searches for those tools. It may also give rise to human error incidents. By scanning the QR code, it is possible to determine whether the person who borrowed the tools has returned them; it will give a reminder if all items have been returned, thus effectively preventing such situations from occurring. 6. Data analysis: Big data analysis is conducted using records of tool loans and returns. By examining the frequency of use and the time spent using various tools, it is possible to determine whether the existing tools meet the production needs, whether there is a surplus of tools, what the rate of tool damage is, and which tools are lacking. This helps in formulating more rational and effective plans for purchasing tools, ensuring that production needs are met while minimizing costs. 7. Automatic configuration tool: If work cards are also managed using QR codes, the tools specified on those cards, along with the records of tool pickups made via those cards, can be automatically identified by the tool management system. This allows for the automatic generation of the tools required for a particular task, thereby preventing situations such as missing tools, borrowing too many tools, or borrowing the wrong tools – and thus improving the efficiency of production preparation.

Zhao Minmin, the mechanical maintenance worker at Jinneng Coal Industry, shook a newly installed sign while going to the winch room in the auxiliary inclined shaft to carry out equipment repairs: “Look, it’s this one.” Point your phone at the QR code on this label and scan it, and many details about this winch will appear right away. ”This is a QR code micro-management system developed by Jinneng Coal Industry’s mechanical and electrical system for surface mechanical and electrical equipment. At present, the company’s main and auxiliary inclined shafts, as well as the main return airway, are all under construction by external teams, which presents various challenges such as a large number of old and outdated mechanical and electrical equipment, and a shortage of maintenance personnel. To overcome these challenges, the young technical staff in the mechanical and electrical systems conducted repeated investigations and discussions regarding the use and maintenance of the equipment on site. They ultimately decided to create a special QR code \"ID\" for each piece of ground-based equipment, by taking advantage of the currently popular \"scan\" function. “We make full use of the cloud storage capabilities on the Internet to collect information such as the names of devices on site, their technical specifications, maintenance requirements, troubleshooting methods, the persons responsible for chartering them, and the personnel in charge of mechanical and electrical operations; this information is then entered manually into the cloud storage one by one. Assign a unique QR code to each switch and device, and display these QR codes on the devices in the form of signs or labels. Managers and maintenance personnel at all levels can use the \"scan\" function to instantly access all information related to the device, eliminating the need for repeated inquiries or searches for manuals; this makes the process convenient and efficient. ” Regarding this system, Guo Chuan, an electromechanical technician from Jinneng Coal Industry, provided an explanation. At present, the company’s mechanical and electrical QR code micro-management system has been piloted in key areas such as the return air shafts, the ducting in the auxiliary inclined shaft construction zones, winch rooms, power distribution points, and generator rooms. More than 50 mechanical and electrical micro-management panels and signs have been installed, along with over 200 maintenance measures and 300 procedures for dealing with faults. During the trial operation period, by scanning the QR code, the company’s wind shaft construction team resolved the issue of leakage causing the feed switch to lock up, while the auxiliary shaft construction team fixed the problem of the disc brake on the auxiliary shaft winch not functioning properly; the benefits of using QR code-based micro-management became evident. In response to issues such as low drawing resolution and the inability to update modifications promptly identified during the system’s trial operation, the company’s mechanical and electrical systems are also being actively revised and improved. Next, the time taken for each maintenance task, the personnel involved, fault conditions, and repair details will also be recorded in detail, so as to ensure that equipment maintenance meets specified standards and achieve zero failures in equipment operation, thereby contributing to the early commencement of joint trials in the mine.

QR codes are everywhere. Here, information related to equipment and materials, as well as instructions for operation and safety measures, are stored for easy reference by users. This is also one of the main functions of mobile phones. At the moment, we only use QR codes for access control and to keep track of work meals; they are not yet used in production, as there are still some areas where the use of mobile phones is prohibited

Many software-generated drawings now also include two-digit codes, allowing all information to be accessed with just a scan – this facilitates on-site installation and quality control, as well as full traceability throughout the process.

QR codes are printed on the products leaving the factory, allowing for quick access to information such as the raw materials used, quality control during production, the manufacturing process, FAT, and other relevant details.