Maths and me @ Data Handling

Data Handling

Data handling is considered one of the most important topics in statistics as it deals with collecting sets of data, maintaining security, and the preservation of the research data. The data here is a set of numbers that help in analysing that particular set or sets of data. Data handling can be represented visually in the form of graphs. Let us learn more about this interesting concept, the different graphs used, and solve a few examples for better understanding.

Data Handling is the process of gathering, recording, and presenting information in a way that is helpful to analyse, make predictions and choices. Anything that can be grouped based on certain comparable parameters can be thought of as data. Parameters mean the context in which the comparison is made between the objects. Data handling usually represent in the form of pictographs, bar graphs, pie charts, histograms, line graphs, stem and leaf plots, etc. All of them have a different purpose to serve. Have a look at the composition of the air that we have learned about in our science classes.

Types of Data

Data handling is performed depending on the types of data. Data is classified into two types, such as Quantitative Data and Qualitative Data. Quantitative data gives numerical information, while qualitative data gives descriptive information about anything. Quantitative can be either discrete or continuous data.

Important Terms in Data Handling

In data handling, there are 4 important terms or most frequently used terms that make it simple to understand the concept better. The terms are:

Data: It is the collection of numerical figures of any kind of information
Raw Data: The observation gathered initially is called the raw data.
Range: It is the difference between the highest and lowest values in the data collection.
Statistics: It deals with the collection, representation, analysis, and interpretation of numerical data.

Quantitative Data techniques : - Inventory management refers to the process of ordering, storing, using, and selling a company's inventory. This includes the management of raw materials, components, and finished products, as well as warehousing and processing of such items.

NEWSPRINT REEL HANDLING

Let us see how data handling help to track materials life cycle - for example Newsprint reels form paper mill to end user here;

Newsprint is basic and costly raw material that consume in large quantity in News paper industry. Newsprint raw material is supplied from paper mill available world wide, mostly industry won't reliable on single vendor. Procurement of consignment from various countries or places were convenient to customer satisfaction is practiced commonly.

We can track materials - Newsprint reels by various methods that are discussed here in brief; [ Barcode / QR code / RFID / NFC ]

BAR CODE

Barcode appear on wrapper of every Newsprint reels. Getting the barcode scanner will ensure you can read any QR Code or Barcode whether it is printed on a label or read off of the screen of a smartphone, tablet, or PC. Our scanners are available in corded or cordless style, which can include connectivity to iOS, Android devices or any Billing Systems online.

Similarly, we have a full selection of Laser, USB, Bluetooth, cordless, portable, wireless, handheld, tablet, in-counter, grocery, and even mobile computer barcode scanners & readers! These Barcode Scanners can read 1D, 2D, and QR codes, and Barcode Readers are compatible with iPhone, iPad, and Android devices.

For example here shown Android device scanned Barcode using QR-Scanner App and result given - 102222700182 as per label. From this we can copy the number or share to some one when result is scanned at one by one.

In India bar code was introduced in 1996 by Ministry of Commerce - we use GTIN -13 / EAN13 barcode system for retail industry. There are verity of barcodes which has their own specification, UPC - 12 digit used in America and Canada, EAN - 13 digit is used in Europe and other Asian countries.

Here shown custom made bar code from WAN IFRA specially for News paper industry in picture, they use 16 digit numbers as explained here.

Following are disadvantage of using Barcode -usually they use numeric values to represent data, this is static information. Generation of code has to follow rules of barcode type they depends, there are questions were all paper mills use same recommended unique barcode as customer required. It is not possible to expect such scenario in all, and also the length move bigger when data code is larger. We can't make customized code with logos but this is possible in QR code.

1 to 8 Reel number - 31307234
9 to 12 Reel weight - 0511
13 Co-packing code - 3 (1 reel/wrapping)
14 Grammage - 1 (40 GSM)
15 & 16 manufacturer code 31

16 Digit IFRA reel number on wrapper
(scanned with QR scanner) = >> 31307234-0511-3-1-31
& >> 51050828-0526-3-0-21

Inside the Newsprint reel core with safer distance to scanner range we can stick this type of Barcode or QR code. This can help to get data of Newsprint reel till end stage, but this is difficult to paste inside the core when it is wrapped. When the reel is ready for production we can stick this code by taking from wrapper re usable sticker.

Either Barcode or QR that can be use in this manner, by which we can track the reel update diameter size caliper details then and then online using software application. By this way copies printed by the reel (consumption - mileage) can be recorded to the database and efficiency of particular material can be checked.

Both Barcode and QR code requires line of sight to scan data, that is scanner and code should be parallel facing each other 90 deg.

We tested both Barcode and QR code placed inside the reel core as shown here, result Barcode is quick responding and not QR code. When angle changed QR code are more sensitive to read, so care has to be taken while placing code sticker inside the core. They requires line of sight while scanning mostly to get result.

Barcode

1. It was developed in 1952.

2. It was developed by Norman Joseph Woodland.

3. It is of 2 types, 1 dimensional and 2 dimensional.

4. It is a way of storing numbers in a printed and computer understandable format.

5. It is used at stores for tracking all purchased items, in hospitals for tracking the records of patients, in rental cars business and tracking of airline luggage, mails and nuclear waste.

6. It is based on Morse Code technology.

7. It requires line of sight.

8. It has lesser data storage as compared to Fastag.

9. Only one barcode is examined at once.

10. It stores information horizontally.

11. It is a vertical arrangement of parallel lines (according to the standard version).

12. It stores less information than QR codes.

QR code

1. It was developed in 1994.

2. It was developed by Masahiro Hara.

3. It is only of 1 type.

4. It is a type of 2D barcode or printed representation of data that can be scanned for data retrieval.

5. It is used in supermarkets, hospitals, cinema or by individuals etc. for transfer of data (sharing contacts, photos, videos and other documents).

6. It is based on Morse Code technology.

7. It requires line of sight.

8. It has more data storage than the barcodes.

9. Only one QR code is examined at once.

10. It stores information horizontally and vertically.

11. It is an arrangement of square dots on square grids.

12. It stores more information than barcodes (it is used to store multimedia data).

Both Barcode and QR code technology is based on Morse code. Morse code is named after Samuel Morse, one of the early developers of the system adopted for electrical telegraphy. Chart of the Morse code 26 letters and 10 numerals. This Morse key was originally used by Gotthard railway, later by a shortwave radio amateur.

International Morse code encodes the 26 basic Latin letters a to z, one accented Latin letter (é), the Arabic numerals, and a small set of punctuation and procedural signals (prosigns). There is no distinction between upper and lower case letters. Each Morse code symbol is formed by a sequence of dits and dahs. The dit duration can vary for signal clarity and operator skill, but for any one message, once established it is the basic unit of time measurement in Morse code. The duration of a dah is three times the duration of a dit (although some telegraphers deliberately exaggerate the length of a dah for clearer signalling). Each dit or dah within an encoded character is followed by a period of signal absence, called a space, equal to the dit duration. The letters of a word are separated by a space of duration equal to three dits, and words are separated by a space equal to seven dits.

Source Wikipedia

Current Barcode Based System and Associated Problems

The state-of-art in today's paper reel management uses traditional barcodes and their associated optical readers. Currently, paper reel suppliers place a barcode label that meets IFRA standards on both the outermost part of the paper reel and on the outermost layer of the wrapping that is placed on the paper reel. The barcode contains all the relevant details about this reel (i.e., manufacturer, factory, machine, weight, length, paper type, and paper whiteness). The barcode is read at every station along the supply chain, as long as it remains on the reel, and the organization's computer system is updated accordingly.

The paper reel passes through many stations along the supply chain. We begin with focusing on the paper reel as it is unloaded at the printing house. At this point an employee checks each reel's quality, reads its barcode, and updates the stock level. The paper reel is then moved by forklift to the main storage area where it is stored until needed. However, due to the bulkiness of paper reels and the storage method (deep stacks), a paper reel may have to be moved or shifted before going to the next station in the supply chain. This is especially true if the printing house is looking for a misplaced paper reel.

When a specific paper reel is needed, its location is identified by the information system. If the information system is accurate, then the reel is quickly located and its identity is confirmed by reading its barcode. If the information system is inaccurate, then a search is conducted for the lost reel until it is found, during which many reels may be moved. Once located, a forklift moves the reel to what is called the daily storage area. Here the reel is unwrapped and left to acclimatize (with respect to temperature and humidity) for at least twenty-four hours. When the reel is needed for printing, its barcode is read again and a forklift moves the reel to the printing press. Here the reel is documented and the printing operation begins. Since the barcode is only on the wrapping around the paper reel and on the outermost part of the paper reel, the reel's identity is often lost at this stage of the chain. Thereafter one of three scenarios takes place:

1. Final Depletion: If the printing operation depletes the reel as much as possible, it is taken to be weighed, and then it and the unusable paper remaining on it are sold for scrap. Due to mechanical limitations the paper on the reel is never used or depleted completely.

2. Partial Depletion: If the printing job is completed before the reel is depleted, it is taken off the printing press and in most cases, is left in the printing area until it is needed again.

3. Paper break: During the printing operation the paper can tear and result in what is called a paper break. Paper breaks are generally the result of a human error, a technical problem in the printing press, or (of most concern to us) defects in the paper reel. This situation is expensive for the printing house since it means that the printing operation must be stopped and valuable time lost. Note that the printing operation is not stopped when going from a spent reel to a new one. It is only stopped for a paper break or when the printing operation is completed. After a paper break occurs the paper must be re-webbed through the printing press and only printing resumes. If the paper break is due to a defect in the paper reel, compensation is available from the paper supplier; however, the reel must be fully identifiable.

The present state of affairs, i.e., the use of barcodes to track paper reels, has a number of drawbacks. These drawbacks were identified and investigated jointly by us and the management of the Yedioth printing house. These drawbacks are:

• Cost of labour: Significant amounts of human resources are invested in reading barcodes, i.e., manually taking a barcode reader, finding and reading the barcode on the reel. In addition, to be able to uniquely identity a paper reel after the printing process begins (i.e., after the last barcode is removed), a paper record must be maintained. A log is kept by manually filling in status forms at each and every subsequent stage.

• Information loss: As mentioned above, once the printing process begins the reel can no longer be identified by its barcode. If perfect records are not kept, then the reel's identity is lost. This loss of identity presents a problem when a defect that is assignable to the paper manufacturer is discovered, especially if it causes a paper break. When a manufacturing defect is found and the identity of the reel is known, then a reimbursement claim can be submitted to the manufacturer for both the defective material and other losses. Moreover, the supplier quality can be analysed with an eye on influencing future purchases.

• Defects and flaws: As mentioned above, despite their size, paper reels are delicate. In fact, defects or flaws can be created in the paper anytime they are handled. With the current barcode based system the exact location of each reel is not always known with certainty and thus there can be extensive handling of reels with a forklift. For instance, it is not uncommon that a reel is moved for printing, only to discover that it is the wrong reel, which must then be returned. Alternatively, a certain reel may be sought, but its storage location is unknown. In such an event, reels must be moved with a forklift to find the desired reel. All this handling has its cost in the quality of the paper that eventually makes its way to the printing press.

• Inaccurate inventory monitoring: Since barcodes are read manually, human error will occur and thus it happens that a reel enters and/or is retrieved from storage without being registered. Additionally, reels that are only partially consumed do not appear on inventory lists. The combined result is that inventory records do not always accurately reflect what is in the paper warehouse.

QR CODE

QR code has more advantage than Barcode, we can make customised setup with logos as shown here. This unique feature separate QR code from others and easy to scan / locate our custom made QR code, more data with alphanumeric can be stored. Easy to generate QR codes in bulk more than 1000 codes per minute can be done using advance software's available in the market.

Bar code and QR code can be read by same machine, even our smart phone tablet can be used for this purpose. When custom made software linked with QR scanning facility then database can be maintain via cloud based and monitor anywhere.

For Example :

We can get overall net weight of balance reels in all plant (Branches) or company. Database can be maintain in that way from purchase of reel to sale of core tracking is easy by online monitoring.

Scanning the QR code get input to the device and directly fetch the database of current status of that particular consignment. By cloud access we can able to edit the dataset with authentication and update the new status quickly.

When getting code with alphanumeric data then it is easy to identify reel/paper variety, GSM, Width and mill with reel code number as show here;

Example ;

7236 / 1 / DA / 0229 / N

[ Reel number / Paper variety / Width / Mill name / GSM ] = 72361DA0229N

We can re-arrange the pattern according to our convenient. Placing our logo in centre of QR code will enhance the appearance and easy for staff to access them.

There are dynamic QR codes which directly link to database and help us to manipulate data easily. Cost of implementing this work is very cheap and economic when comparing with RFID tracking.

What Are The Main Differences between RFID Tags and QR Codes?

There are quite a few differences between Radio Frequency ID Tags and QR Codes. In this section, we will look at some of the overarching differences between these two technologies.

Read Distance

As you have probably gathered by this part of the guide, these two technologies have drastically different read distances. Depending on your RFID Frequency you may have anything between a few centimetres to 100+ meters. A QR Code however is typically read directly in front of a reader, due to them typically being a form of camera that needs to focus on the ‘image’.

Trackable vs Static

One of the core differences between RFID Tags and QR Codes is that one is much more trackable and can be used in logistics, security, and other mobile operations. RFID Tags can be tracked and give real-time information and updates. A Quick Response Code on the other hand is static and information is only transferred when it is manually scanned.

Line of Sight

QR Codes have a disadvantage to an RFID Tag as they require a line of sight to be scanned. This can prove difficult depending on your choice of application. For a lot of businesses they may require proximity but not strictly line of sight, so QR Codes can be limited. If you are using a reader for pedestrians and people approaching on foot, then this issue is negated as they will be close enough to scan their code.

RFID Tag vs QR Code

Technology

It is fairly obvious that these two different systems use different technology. RFID uses radio, to which there are a few different frequencies with their own uses vs QR which uses optics (lasers). QR Codes are easier to make however and could prove more accessible to smaller businesses. The industry you are in and core intended use will help you decide which is a better fit.

Interference

As with anything, both technologies have some susceptibility to being interfered with. In the case of QR Codes, it can be as simple as physical obstruction such as a tear, some dirt, or the phone screen being too dim. For RFID, interference can depend on the type of frequency being used for instance liquids and metal can impact certain frequencies.

Human Management

Broadly speaking a QR Code system normally has some kind of human managing the system physically, either helping the users scan their codes, or ensuring it is running smoothly. On the flip side, RFID systems are often unmanned as a whole with fixed readers being automated and not requiring much human involvement and management.

RFID'S

Radio frequency identification (RFID) systems for the paper industry is an emerging research topic due to the need for an automated identification system for the paper industry which would carry on the identification codes of paper and board reels throughout their life cycle. Challenges, benefits, and the application environment of using passive UHF RFID systems in the paper industry are presented and discussed. The major challenges are development of globally operable tag antenna designs and integration of reader units and reader antennas to paper handling machinery. To confront and solve these challenges, this paper presents novel tag antenna designs for paper and board reel identification and proposes solutions for reader and reader antenna integration to paper handling machinery. In addition, the identification locations within the paper reel supply chain and the effects of RFID systems to supply chain visibility are presented and discussed. In addition, test results of using passive UHF RFID systems in the paper industry environment are presented. Note to Practitioners—An automated identification system, which would carry on the identification code of a specified paper or board reel throughout its life cycle, is needed in the paper industry.

UHF RFID is integrated in paper core at paper mill permanently and data is updated then and then when needed, after paper is re-wound data is updated or wrote into the memory chip of RFID about reel number, batch, GSM, length of web and weight.

RFID in Life-Cycle of Newsprint reel;

Integration of UHF RFID into paper core permanently.
Writing data to paper reel ready for dispatch.
Tracking the movement/transfer of consignment using RFID tag.
Monitoring reel in conversion process and recording mileage.
Checking paper core after production and returning back to paper mill for re-use.

Nowadays when barcode identification systems are used the identity of the reels disappear when the wrapping of the reel and at the same time the barcode are removed. The RFID tag, however, would be attached to the paper reel core and thereby the identification code of the reel is restored throughout its life cycle.

RFID systems would benefit the paper industry by enhancing the supply chain visibility and providing a more automated identification system than barcode identification. In the future, paper reels will be identified with clamp truck-integrated reader units which, on the other hand, enables adding more real-time information about the locations of the paper reels to information databases but also sets challenges for paper reel tag performance and integration of RFID reader units and reader antennas to paper handling machinery. This paper concentrates on passive UHF RFID systems and their application to the paper industry.

RFID technology

How UHF RFID Reader & tag communicate

Powering on: When the handheld UHF RFID reader is powered on, it starts scanning for RFID tags in its proximity.
Scanning for tags: The reader emits radio waves at a specific frequency, typically in the range of 860-960 MHz, continuously or periodically. These waves create an electromagnetic field around the reader.
Tag detection: When an RFID tag comes within range of the electromagnetic field, it absorbs some of the energy from the radio waves and uses it to power up its integrated circuit (IC).
Communication: The powered-up RFID tag now has sufficient energy to respond to the reader. It sends back a unique identification number or other data stored in its IC, using the same frequency as the reader's radio waves.
Reception by the reader: The handheld UHF RFID reader detects the response from the tag using its built-in antenna. It processes the received data and can display the information on its screen or transmit it to a connected system.
Multiple tag handling: The reader can scan multiple tags simultaneously within its range, allowing the identification of multiple items without requiring individual scanning.
Data transfer: The reader can store the read data internally or transmit it wirelessly (e.g., via Bluetooth, Wi-Fi, or cellular) to a computer system or database for further processing and analysis.

A handheld UHF RFID reader uses radio waves to detect, read, and interact with UHF RFID tags. It employs antennas, communication protocols, and processing capabilities to wirelessly transmit and extract data from the tags for various applications like asset tracking, inventory management, and supply chain optimization. UHF RFID technology enables longer reading ranges (up to several meters) compared to other RFID frequencies, making it suitable for applications requiring more significant reading distances, such as inventory management, asset tracking, or access control.

UHF RFIDs tags ;

RFID tags are small electronic devices that store information and communicate with other devices using radio waves. RFID tags are used in a variety of applications, from tracking inventory to monitoring the movements of livestock.

It consist of micro chip (Black) and antenna (Brown) as shown above, micro chip stores data and antenna help to communicate data with reader.

Compared picture size of both RFID and Barcode, various size and pattern of RFID tags are available in the market.

RFID with Barcode combination

UHF RFIDs

UHF RFIDs in WMH [Warehouse material handling ] ;

Layout of Printing industry with RFID reading gate;

There are a total of four readers: at the entrance to the paper reel storage area, in the transfer from paper reel storage area to daily storage area, in the transfer from the daily storage area to the printing area and at the exit from the printing house. Note that the paper is vertically stacked in the paper reel storage area and is horizontally stored in the daily storage area.

UHF RFID readers comes with range INR.6,000 - 40,000, when moving with Gate reader it cost around INR 1,15000 approx. Tags are cheap starting from INR.5.50 per tag, then computers and software application cost to handle thing will cost little bit higher. There are handheld device also available in the market as shown below INR. 35K to 50K

Here YouTube content on RFID enabled warehouse for Newsprint reel is discussed, instead of text explanation it is more convenient to understand by watching this video clips.

RFID Reader in paper mileage;

RFID not only used for tracking materials, Using advance readers we can also record the RPM of reel in production (Real time), as we said RPM give reel mileage and weight by formula it is easy to update current status of reel and also copies output we get.

Using target detection method detecting the location of the tag with respect to the reader is possible . We can consider the two perpendicular axes, the abscissa and the ordinates. The reader will be in the origin and the tag is anywhere else (example in the paper core). The location is defined by knowing the distance between the origin and the tag, and the angle between two lines: the ordinate, and the line passing between the reader and the tag. By knowing the distance and the angle, the location is detected accurately.

Whenever reader gets pulse on angle change detected then coder unit count pulse per second and convert it to RPM - after analysing this RPM of Newsprint reel while production it is easy to generate mileage report like - paper thickness, weight and length of web.

Here shown multi sensors identification chips information from reader unit result displayed on computer screen - speed, residual meter (balance reel length) and weight in real time. In this blog page Newsprint measures, I provided real time calculator for the same. Like RPM diameter of reel is taken into consideration were these two are interlinked as discussed in home page RPM to diameter calculator.

NFC [Near Field communication] ;

Near-field communication (NFC) is a set of communication protocols that enables communication between two electronic devices over a distance of 4 centimetres (1.6 in) or less. NFC offers a low-speed connection through a simple setup that can be used for the bootstrapping of capable wireless connections. Like other proximity card technologies, NFC is based on inductive coupling between two electromagnetic coils present on a NFC-enabled device such as a smartphone. NFC communicating in one or both directions uses a frequency of 13.56 MHz in the globally available unlicensed radio frequency ISM band, compliant with the ISO/IEC 18000-3 air interface standard at data rates ranging from 106 to 848 kbit/s.

We can say NFC is short range communication device, our Bank credit/debit card use this type of NFC tag inbuilt -so it can communicate with POS machine in shops. Large data communication with short range..

Near-field communication was developed by Sony, Nokia, and Philips; their combined forum monitors and regulates the NFC standard. Near-field communication operates at a low power, low-frequency range.

Frequency: 13.56 MHz Range: 0 to 10 CM

Specification: ISO/IEC 14443 (For smart cards which store information) and ISO/IEC 18000-3 (For RFID tags in smart devices)

NFC doesn’t require power to operate
Works with inductive coupling
NFC can do two-way communication
NFC Has larger storage space compared to RFID
Suitable for single-device communication

NFC was originally developed to use file transfer purposes between Smartphones using the Android beam

NFC tag is like RFID tags that cost little bit higher starting from ₹15.00 & reader around ₹6000.00

Conclusion;

Data storing and range to receive / access it is a main functions of above discussed technologies, for small spares we can use Barcode or QR technology (were line of sight scan is possible). But in case of large consignment like Newsprint reel RFID or NFC can be implement/embedded ,were it can read / write large data easily from proximity range. Also the size and weight of Newsprint reels in warehouse stock area, we are not able to reach to scan from Barcode/QR code from wrapper some time. So range should be more to keep accessing these materials (were not possible for line of sight scanning).

Tracking the material and keep updating through out material life-cycle is possible with RFID as current status of reel location, reel details like size, GSM, length, weight, thickness and copies output has to be communicate with the inventory and managerial staff to take decision. And this is possible with latest proximity sensor like devices / technology - RFID / NFC / BLE (Bluetooth Low Energy) / GPS.

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