Presentation on theme: "Barcode Label Error Proofing & Manufacturing Information Systems Buffalo-Niagara Emerging Technology Awards Manufacturing Achievement Finalist - March."— Presentation transcript:
Barcode Label Error Proofing & Manufacturing Information Systems Buffalo-Niagara Emerging Technology Awards Manufacturing Achievement Finalist - March 25,2004
Data N Able 2 1. BACKGROUND 2. OBJECTIVE 3. INVESTIGATION OF CURRENT SITUATION 6. ACTIVITY SCHEDULE 5. VERIFICATION OF RESULTS 4. CORRECTIVE ACTION – Implement Pack Across Your Business CHANGE METHODOLOGY STORYBOARD Error-proof with DATA N ABLE Label errors are unacceptable. New programs must be launched with zero defects. Implement a Scanning System to error-proof for 100% Label Quality. Labeling System Only Used for Printing Labels No Quality Tracking Database Mislabeled Product Shipped to Customers No Test Data for Good vs. Bad Product Batch Printing of Shipping Labels Wrong Shipping Labels Applied to Packs Pack System Details Completed C-Zone Radiators A-Zone Radiators D-Zone Radiators VB (P-90/GMT) Utilizes 2D Data-Matrix bar-coding to serialize all manufactured parts for Quality traceability. How the system works: –Every part is individually labeled with a unique serial number. –Label is scanned prior to each test and results are stored in database. –Every part is scanned during the pack process to assure test result. –Parts can only be counted in the pack for successful test result. –Model number and pack quantity is verified through the database. –Only after all criteria is verified is the shipping label printed on demand. Shipping Label Product Label Implementation Timing Scheduled VB Line 2 (March) Toyota Radiators (April) I-Cell Condensers (May) B-Zone Condensers (July) 0 Label Errors All PTC hardware is purchased and on site. Vacuum Braze and Toyota are in Debug Phase. Buffalo-Niagara Emerging Technology Awards Manufacturing Achievement Finalist - March 25,2004 Breakthrough Technology Database Information is Real-Time Web-Site on factory floor
Data N Able 3 Data N Able Systems Manufacturing Information System How the system works: –Every part is individually labeled with a unique serial number. –Label is scanned and PLC data and results are stored in the database. –Every part is scanned during the process to assure test results. –Parts can only be counted in the pack for successful test result. –Model number and pack quantity are verified through the database. –Only after all criteria is verified is the shipping label printed on demand. –Each shipping label can be re-verified at shipping dock to assure Customer Satisfaction. –The system is modular so it can easily be tailored to meet your needs Utilizes 2D Data-Matrix bar-coding to serialize all manufactured parts for Quality traceability. Added Quality Benefits include: Quality Data stored is in MY SQL Server Data Base for life of part. Real-Time Information is available on factory floor and managers desktop. Web-site information can be available for customer warranty retrieval.
Data N Able 4 Data N Able Systems Manufacturing Information System The 2D Data-Matrix Part label is uniquely serialized for part traceability. 8 digit part number 3 digit model number Unique serial number Date 2D barcode that will be scanned during the production and testing process Part Number Model Number The system is proven and has processed over 50 million labels in a five year period with a 99.8% uptime and a 98.5% first time read rate throughout production. FAQ’s about 2D Bar-coding What is it? A 2 dimensional “checkerboard” barcode. Why use it ? More data can be embedded in a smaller space. It can be scanned at virtually any orientation for easy reads. It has built in redundancy so up to 25% of the code could be damaged and still be readable. The Part Label and Pack Label are linked together and cross verified through scanning and the database information.
Data N Able 5 Data N Able Systems Manufacturing Information System –Provide operator feedback and control. –Interfaces to the machine PLC for control and to capture plant floor information. –Interfaces to up to five HHP 2D Data- Matrix imaging scanners. – Uses the Socket.com Quad serial port card to bridge up to five machines into one terminal. –Supplies Ethernet connection to the Plant Floor Server. –Triggers the On-Demand Printing of Shipping Labels and updates the Production count in real-time. The information gateway to the plant floor is based on breakthrough Windows CE technology. The Pack Screen is the main operator interface to give feedback to the machine operator as to the status of the part and the pack. The information gateway of the System is a GE Fanuc ViewStation CE 6” industrial computer which acts as to:
Data N Able 6 Data N Able Systems Manufacturing Information System Hand Held and fixed mount scanners are used to manually and automatically scan barcodes in the pack and in machines. The Hand Held Products 4410LX is capable of reading all 1D and 2D bar- code symbologies. There are no lasers used to read the bar- codes. A CCD camera based scan engine is used to take a picture of the image and then decode it. This allows scanning at many angles. The configuration of the scanner including baud rate, symbologies, and # of characters read can be stored in a clone 2D setup code. This can be shot one time to reconfigure a new scanner in seconds on the floor. In addition this code is embedded on the operator panel and can be read directly from the screen.. HHP 4410LX - 2D DataMatrix Imaging Scanner Break Through Technology This picture was actually taken with the scanner itself.
Data N Able 7 Data N Able Systems Manufacturing Information System The Floor Server interfaces into a SQL Database. One server handles an entire department with multiple cells. Cells are setup through a touch- screen by model number. All data is retrieved from the database to be printed on the shipping label. Select the Cell Setup screen by touching the Cell Setup banner bar. Real-Time On-Line Information available on the Plant floor and Managers desktop through web based technology. DNA SYSTEMS
Data N Able 8 Data N Able Systems Manufacturing Information System Cell Statistics – Display of real-time production information as well as the current test & pack status including scan results. The tester is shown on the left status box with the total number of cycles completed shown. Screens can be easily customized for your application with multiple machine / scanners into one touch screen to provide real-time production counts to your desktop. The pack station is shown in the middle status box with the number packed and pack count displayed. As parts are packed the pack will show the percentage completed and real- time production counts for each cell and department. The right status box displays first time read rates and scanner data.. Cell Status Screen for Real Time Feedback Display
Data N Able 9 Data N Able Systems Manufacturing Information System Manufacturing System Website Overview. On-Line information includes Real-time production counts by Cell #, shift, and model number. To view on-line production counts select the department and date range on the interactive popup calendar. Select a day, week, or month and once the form is complete, press OK. The results are displayed in the format shown below. Actual Website Graphics To calculate the number of parts produced in each department or cell by Model, per shift or day, use Part Count By Department. Complete this form by entering the department of interest as well as a day or range of days. Information is totalized at the end of each shift to show individual shift counts by department.
Data N Able 10 Data N Able Systems Manufacturing Information System Manufacturing System Website Overview. The SQL Data Base can be queried on-line to show all department activity through each machine. To view current or past activity in a department use the Station Events By Department form. This operation returns the most recent activity in a department. Results can be filtered to include a specific cell, station, event and/or time & date. This query returns the following results. In these results a part’s path is examined by looking for the same serial number in the Part Serial Number field. This example shows a single part highlighted.
Data N Able 11 Data N Able Systems Manufacturing Information System Manufacturing System Website Overview. The SQL Data Base can be queried on-line to show Real-time Quality data for every machine in a department. This query returns the following Quality results: Parts tested, passed, failed and re-tests. It then calculates First Time Test & Overall Quality in real time. This delivers instant access to process control on the production floor. It provides for immediate response for Quality Control to react.
Data N Able 12 Data N Able Systems Manufacturing Information System Manufacturing System Website Overview. The SQL Data Base can be queried on-line to trace a part or packs history through each step of the process. This query returns the results for all parts produced during a certain time period. In this query all parts produced are displayed by the Pack Serial Number field for complete quality traceability. The History By Part form performs a search for an individual part throughout the process automatically. This provides quality data traceability for every part serial number and the part’s originating department as well as date and time produced.
Data N Able 13 Data N Able Systems Manufacturing Information System Let Our Vision... Be the Vision of your Future ! Plant floor data on your desk in real-time.