The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Automatic Identification and Data Capture

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Outline n why use automatic identification? n technologies – bar code – cards – radio frequency tags – other n applications

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Why AutoID? n identify items n eliminate errors in data collection n speed up data collection n track items n store information about items

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros AutoID Technologies n bar codes – 1D (linear) – 2D (stacked or matrix) n cards – magnetic stripe – smart – optical n radio frequency tags n contact memory n voice

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros 1D (Linear) Bar Codes n most widely used technology n bars and spaces n may be numeric or alphanumeric n low storage capacity (15-50 characters) n usually used as “license plate” n most used codes: UPC, I-2/5, Code 39, Code 128

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros UPC Code n retail applications n numeric, 12 digits n format format – a character has n 2 bars and 2 spaces n 7 modules (bar, space is 1, 2, 3 or 4 modules wide) n dark module = 1, light module = 0 – left and right are different

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Interleaved 2 of 5 Code n industrial applications (distribution) n numeric, any even number of digits n format format – start and stop characters are different – a character has n 5 bars or 5 spaces n 2 are wide, 3 are narrow n odd digits are bars, even are spaces

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Code 39 (3 of 9) n industrial applications n numeric and upper case alpha, any length n format format – start and stop characters are the same – has intercharacter gap – a character has n 5 bars and 4 spaces n 2 bars and 1 space are wide

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Code 128 n industrial applications n full ASCII character set, any length n format format – different start and stop characters – uses a check character for error detection – a character has n 3 bars and 3 spaces n 11 modules total (bar, space is 1, 2, 3, or 4 modules wide)

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros 2 Dimensional Barcodes n Portable Data Base n Formats – Stacked – Matrix n PDF417 PDF417 – stacked code – up to 2000 characters – error correction

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros 2 D Barcodes (cont.) n Data Matrix Data Matrix – matrix, up to 500 characters, error correction – scaleable down to.001 in square – marking small items – IC’s, single dose meds n Maxicode Maxicode – matrix, 93 characters, error correction – 1 inch square, locating bullseye – package sortation and tracking

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Bar Code Readers n handheld or fixed mount n contact wands (pens) – slow, inexpensive n laser scanners – longer distance scanning – fixed or handheld – can read stacked bar codes n image scanners – fixed or handheld – can read stacked bar or matrix codes

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Cards n magnetic stripe – low cost – low storage capacity – contact reader – can be rewritten – easily damaged (less easily for high coercivity stripes) n example: credit cards, bank cards

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Cards (cont.) n “smart cards” – imbedded microchip n memory only – stored value cards n microprocessor – high storage capacity – can be rewritten – can execute programs n example: some credit cards

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Radio Frequency Tags n transponder (tag) is programmed with information n reader has an antenna which sends radio signals to activate tag, read or write it n types of tags – active (has battery) n read and write – passive (activated by reader) – often read-only n noncontact, non line-of-sight

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros RFID Applications n railroad cars, commercial trucks n automobiles on assembly lines n parts carriers in hazardous environments n toll collection on highways n theft prevention in retail

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Why RFID? n tags can be used in harsh conditions – usually housed in protective packaging n tags can be read over distances greater than 90 feet n tags can be read through snow, grime, cutting fluid, paint, etc. n tags can be read at high speed n more costly than bar code n lack of standardization between manufacturers

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Contact Memory n a memory chip in a stainless steel case that resembles a button battery n read by touching the case with a probe n read only or read-write n license plate or portable database n additional capabilities can be built in – real-time clock – temperature sensor – cryptography

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Use of Contact Memory n asset tracking n access control n digital cash n maintenance records n store manufacturing history for products

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Voice Data Collection n hands free n easy to use n must be “trained” to recognize operator

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Some AutoID Applications n Ford Engine plant n Nabisco warehouse n Ryder trucks n Bigwords warehouse n other applications can be found in: – Supply Chain Systems Magazine Supply Chain Systems – Modern Material Handling Magazine Modern Material Handling

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Ford Engine Plant n RFID tags: manufacturing info and test data

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Ford (continued) n Essex Engine Plant, Windsor Ontario Essex Engine Plant, Windsor Ontario n 700,000 engines/year, 12 varieties n engine work sequence loaded into the tag n each station asks tag for its operations n test data written to tag source: Supply Chain Systems Magazine

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Nabisco n order picking in warehouses order picking n picker logs on by voice n system asks for truck number n system speaks SKU and quantity n picker says “got it” to verify pick source: Supply Chain Systems Magazine

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Ryder n tracks maintenance records on rental vehicles n stores customer name and odometer reading n stores fueling info n contact memory contact memory

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Bigwords.com n college textbook e-tailer college textbook e-tailer n key issues – speedy delivery – order accuracy – peak at start of semester – few weeks source: Supply Chain Systems Magazine

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Bigwords.com Order Flow n order taken on web site – if in stock, order transferred to WMS at the DC – else, EDI to publisher, usually ships same day n incoming books scanned, add to inventory n picking – RF terminals – combo pack list/ship label printed – formatted for UPS, USPS, etc. – pickers take “waves” of labels – scan book bar code – place in carton, put label on carton – scan label to confirm order complete

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Bigwords.com (cont.) n electronic manifesting system – tracks shipment through package carrier – does verification scan of label n benefits – speed – up to 25,000 orders on a peak day – high order accuracy, 99.9% inventory accuracy

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Bigwords.com (cont.) n how? integration of systems

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Facility Layout and Material HandlingD. J. Medeiros Summary n AutoID systems provide many capabilities: – identify and track products – store information about products – allow real-time data collection n Information is a valuable asset n AutoID speeds information flow