Right Filter,
Reliable Production Assurance
In the project implemented at PMI's cigarette manufacturing plant in Izmir Torbali, traceability and correct material usage were targeted at the stage where filters produced in the filter plant are fed into cigarette production machines.
Secure matching from filter to production
In the project implemented at PMI's cigarette manufacturing plant in Izmir Torbali, traceability and correct material usage were targeted at the stage where filters produced in the filter plant are fed into cigarette production machines.
The project was carried out to secure filter-work-order matching throughout the flow from filter production to cigarette production.
Error and quality risk in manual checks
In cigarette production, the filter fed into the machine had to be compliant with the related work order and product recipe (BOM). Manual verification increased quality risks.
- 01SKU ComplianceManual checking of whether the fed filter had the correct SKU carried error risk.
- 02Expiry ValidationManual verification of filter expiry date suitability was not reliable or sustainable.
- 03Start-up AssuranceA systematic structure was needed to prevent production from starting before matching was confirmed.
Automatic matching control with RFID + SAP + PLC
Filters were labeled at the filter plant output with production date, expiry date, quantity, and SKU data. During feeding to the cigarette production machine, SAP work order and BOM data were read and automatically matched with filter material code.
Filter Labeling
Production date, expiry date, quantity, and SKU information are written on each filter.
Work Order Reading
At machine feeding, SAP work order and BOM data are read.
SKU and Expiry Matching
RFID-read filter data is compared with SAP material code and expiry criteria.
Machine Run Permission
If SKU and expiry criteria are met, the PLC grants run permission; otherwise production is blocked.
Field verification and machine control infrastructure
RFID Readers
Read critical tag information instantly when the filter is fed to the machine.
PLC Structure
Control layer managing field automation and machine run-permission decisions.
Handheld Terminal
Used for field verification and operational data handling tasks.
End-to-end SAP work-order validation
The system works integrated with SAP; work order, BOM, and filter material code are received from SAP and matched with filter tag data, while matching and machine-permission outcomes are associated back with SAP.
Filter material code, work order, and BOM data are retrieved from SAP and automatically matched with RFID reads.
Matching outcomes are sent to the PLC layer and run-permission decisions are applied in real time.
Automated validation that strengthens quality assurance
Wrong SKU Prevention
Automatic filter-work-order matching prevented incorrect filter usage.
Expiry Compliance
Filters with unsuitable expiry status were blocked by the system.
Operator-Independent Control
Preventing machine run before matching improved quality assurance.
Would you like to digitize filter and material validation processes?
Let us adapt RFID-based traceability and work-order validation solutions to your factory.
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