Coding Systems For Lean Production
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How can coding technology help to deliver leaner production? Linx Printing Technology has the answer.
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Coding Systems For Lean Production
- 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. Wastes in a manufacturing process x Z ZZ ZZ Z Z Waiting Quality Defects st 1 Unused Creativity 1,2, 3,4, 5,6 Overproduction Motion Inventory SH RU ! Transportation De-Burring Processes
- 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 overproduction – 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 • 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 • Twinings Tea – Move from mask laser to scribing laser – No need to change masks – 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!