Coding systems for lean production: waste reduction, increasing flexibility and productivity

1. Coding systems for lean production:
waste reduction, increasing flexibility and productivity
Charles Randon, Senior Product Manager, Linx Printing Technologies

2. Coding systems for lean production
Overview
• What is “lean” manufacturing
• The role of coding and marking in production
• How coding solutions are changing
• Where coding fits with lean manufacturing
• Real results from leaner coding
• Questions
2

3. Lean Manufacturing can make your company
more competitive and more efficient
“Lean” principles:
• Maximise value for customers
• Minimise waste
• Focus on “value streams” across a
business, not individual products
and departments
“Lean” Benefits
• respond to changing customer
demands
• higher quality
• lower costs
• faster throughput times
3

4. ZZ
ZZ
Z
Z
Z
Waiting
1,2,
3,4,
5,6
Overproduction
1st
Unused Creativity
x
Quality Defects
Motion Inventory
De-Burring
Processes
Wastes in a manufacturing process
RUSH!
Transportation

5. Lean principles link to Overall
Equipment Effectiveness (OEE)
• OEE aims to reduce and/or eliminate “Six Big
Losses”
• most common causes of efficiency loss in
manufacturing
– Breakdowns
– Set up and adjustments
– Small Stops
– Reduced speed
– Start up rejects
– Production rejects
• These link to the “wastes” that lean
manufacturing wants to minimise

6. Coding and marking in manufacturing
• “Coding” on primary and secondary packaging
• Why code?
– Legislation
– Customer requirements
– Traceability
– Product identification

7. What’s your view on coding?
• Bottleneck on the line?
• Causes rework?
• Needs frequent maintenance?
• Long set up and change over times?
• Necessary but doesn’t add value?
– Waiting time, defects, transportation,
over-production

8. Coding technology is changing
• Reducing waiting time
– Maintenance: less frequent, less
downtime
• Longer intervals between scheduled
maintenance
• Quicker, easier maintenance procedures
– Self maintenance, mistake proof
consumables changes, wash down
designs
– Product changeovers: quicker, fewer
mistakes
• Fixed “analogue” to variable “digital”
coding technology – from hardware
changes to the press of a button
• Increased memory storage
• Multiple line settings as well as code
content in memory
• Increased mobility

9. Coding technology is changing
• Reducing defects
– Code content: more mistake proof,
more intuitive
• Simple code creation and editing
– Touch screen user interfaces
– On-screen help
– copying code content and set up
between coders using USB
– Limited editing for individual users
• Automated code selection and editing
– Barcode scanner linked to coding
equipment
– Links to PLCs
– PC control – from web server to
integration with IT systems

10. Coding technology is changing
• Reducing processes and over-
production
– Less need to fit processes around
coding equipment
• Minimal start up procedures, no
need to leave powered or run every
day
• One coder for several applications
– less variation, inventory
• Coding from any direction – less
product handling
• Mobile coding – no need to have
coders “plumbed in”

11. Real life examples
• R Ceravolo - fruit and vegetable packing
– Move from labelling to digital coding
– Extra process removed – coding in line
– Faster throughput (from 300 to 1000
units/day)
• Next Gen Pet Foods
– Product changeovers quicker by using
coding to apply more data to the pack
– Reduced pack inventory – more generic
packaging
– Output doubled
– Added value in being able to run on-pack
promotions

12. Real life examples
• Twinings Tea
– Move from mask laser to
scribing laser
– No need to change masks
– Less waiting time
• Wet Fix - bottled water
– More consistent print, fewer
manual quality checks
– Less daily printhead maintenance
– Use one printer on several lines
– Fewer defects, less waiting time

13. Real life examples
• Pharmaceutical contract packaging
– Several printers connected to one PC
– Less set up time for each batch
– Codes controlled by one manager
– Less waiting time, fewer defects, and
more management information
• Dried foods packaging
– Printers are mobile and interchangeable
– Use one printer on several lines, with fast
changeover
– Less waiting time, less transportation (and
less purchase cost!)

14. Tips for coding solution evaluation
• Run a trial
– Make sure the coding equipment really
does eliminate waste
• Don’t just look at the coder in isolation
– Look at how it can help eliminate waste in
the whole production process
• Ask your supplier about real lean
examples
– Benefit from their experience
• New coding equipment can pay back very
quickly
– Look at total costs of ownership

15. Summary
• Lean manufacturing maximises value and
minimises waste
• Coding solutions have changed to support lean
principles
– Reduced waste: less waiting time, fewer defects,
less over-production, fewer processes
• Coding solutions can help you to get leaner:
– respond more quickly to changing customer
demands
– achieve higher quality
– reduce costs
– Increase productivity

16. Take a fresh look at your coding solution!

17. Thank you
Any questions?