The document discusses bar code scanning and work-in-process (WIP) systems. It explains that bar codes contain predefined information that can be scanned automatically and accurately to collect real-time data. WIP systems track details about jobs like what is being worked on, its location, tasks completed, employees involved, and time/output metrics. The document provides examples of how bar code scanning and WIP systems can be implemented in manufacturing processes like tire production to track materials, production stages, and finished goods.

1. Bar code
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Bar code Scanning

3.  Also known as "WIP Systems,"
 It is an automatic identification technology
 Bar code is a predefined format of dark bars and white s
paces
 Structured to contain a specific piece of information
 It allows real-time data to be collected accurately and
rapidly
 Combination of barcode technology with computer and
application software improves performance, productivit
y and profitability

6.  MANUAL METHODS  AUTOMATIC METHODS
 KEYBOARD OPERATI  OPTICAL CHARACTER RECOG
ON NITION
 MAGNETIC INK
 1 ERROR/300 CHARA
CTERS  MACHINE VISION
 RADIO FREQUENCY IDENTIFI
CATION
 SMART CARDS
 BAR CODE

7.  REPRESENT UNIQUE IDENTITY OF A PRODUCT
 ACCURACY OF DATA INPUT (ERROR FREE)
 AID EFFECTIVE MANAGEMENT OF RESOURCES AND
INVENTORIES
 LABOUR SAVINGS BY AVOIDING MANUAL SYSTEM

8.  COST EFFICIENT
 REAL TIME DATA COLLECTION
 MEASUREMENT OF W.I.P. THROUGHOUT THE FACTORY
 RAPID ACCESS TO TOTAL PRODUCTION COSTS
 MORE ACCURATE DISPATCH.

11.  A device used to extract information optically from
a Bar Code
 Bar Code symbol consists of series of vertical
dark bars separated by light spaces
 When illuminated reflected light is detected by
electro optical sensor
 The intensity of reflected light from the dark bars is
less than that of spaces

12.  Reflected light is converted into electrical voltage
signals
 Analog voltages are digitized into raw data
 The decoder converts this data into the character
data representation of the symbol’s code

13.  CONTACT READERS
 Musttouch or come in cl
ose proximity of symbol
 Good where the label can
not be placed in an easy-t
o-view position
 Normallyhand-held/stat
ionary units
 Common type is pen/wa
nd reader

14.  A low-resolution wand may not
be able to recognize a narrow ba
r of high-density symbol
 Positioned angle of wand to the
surface and movement speed ac
ross the symbol are key paramet
ers
 A high-density resolution wand use
d to read a low-density symbol mig
ht see an ink spot as bar or an ink v
oid as a space

15.  Reader need not come in contact with sy
mbol
 Scan distance may be from 6” to several f
eet depending upon symbol size and scan
ner design
 Hand-held, fixed beam readers

21.  INVENTORY CONTROL
 Portable readers
 W.I.P. COMPANY INVENTORY
 Raw materials
 WIP (Components, Assemblies, Semi finished
Products)
 Finished Products

22.  SHIPPING
 WARE HOUSING
 ELECTRONIC DATA INTERCHANGE (EDI)
 Direct communication between computers of tw
o companies (Manufacturer & Vendor)
 Industry-wide EDI standards
 Reduces cost and saves time of business transact
ion

23.  RETAIL APPLICATIONS
 Super markets
 Counter-mounted Bar Code scanners
 Universal Product Code (UPC)
 Price and description information
 HEALTH CARE APPLICATIONS
 Drugs, devices, instruments
 Identification of expiry date
 Blood banking
Blood group
Expiry date
Donor traceability

24. APPLICATIONS …

25. In somewhat simple terms, a WIP system might
record and responses to:
 What (what thing or job?)
 Where (where it is/was it located?)
 Task or operation (what work was done?)
 Who (who did the work?)
 Duration (how long did it take them?)
 Output (how many units were produced and/or scra
pped?)

26.  EFFECTIVE MANUFACTURING PROCESS
NEEDS EACH TIRE BAR CODED
 TWO LABELS PREFERABLY
 LABEL TO CONTAIN
 BATCH DETAILS
 MFR DATE
 TIRE SIZE
 CUSTOMER CODE
 ISBN (International Standard Book Num
ber) BAR CODE COULD BE USED.
 Establishes and identifies one title from
one specific manufacturer and is unique
to that manufacturer.

27.  There are two basic types of manufacturing: dis
crete and process.
 Discrete manufacturing (auto manufacturing)
relies on a (BOM) to identify the large number
of specific parts or subassemblies and their qu
antities.
 Process manufacturing (e.g., chemical processi
ng) is formula-based. It relies on weights and m
easures (pounds or gallons) of raw ingredients.

28.  RECEIVING
 RAW MATERIAL INVENTORY
 PICKING
 WIP
 PRODUCT IDENTIFICATION
 FINISHED GOODS
 SHIPPING

29. Mixing the materials
Natural and synthetic rubber are
combined with carbon black
Extruding the tread
The extruders produce a continuous sheet of
tread rubber, which is then cooled and cut to
specific tire lengths
Weaving the plies
Spinning cords such as rayon, nylon, steel
and polyester undergo a process called
“calendering”, where they are coated with
rubber on both sides.
Preparing the bead core
The bead core is formed by aligning, and
then coating plated steel wires with rubber

30. Vulcanization
The “green” tire is placed in a curing press
for a certain period of time (10-15 minutes)
at a specific pressure and temperature
The building process involves two stages.
Stage 1: Beginning with the woven sheets, the inner liner, body plies and sidewalls are
placed on the building drum.
Stage 2: The tire is shaped by inflating the rubber and applying side tread rubber, two steel
belts and a cap ply to achieve a "green" tire.

31.  Final inspection
Each tire is visually and electronically
inspected for balance, quality and
uniformity. This final check ensures
consistent and reliable performance.
Ready for Shipping
Finished Goods

32.  DATABASE PROGRAM LINKS THE BAR CODE TO THE TIRE P
RESS MACHINES
 AUTHORISED ID CARD INCLUDES BAR CODE
 Card could be used by workers.
 OT (Over time).
 Monthly payment report.
 OT calculation.
 Section in-charge approvals.
 Attendance ID card.
 Serial number of worker and department he works.
 BAR CODE READER IS INTERFACED WITH THE COMPU
TER FOR TRACKING OF TIRE.

33.  THE TYPICAL SEQUENCE WOULD BE
 Database creation (OPAC)
 Generate Bar Code for all Press Machines.
 Installation of suitable scanning equipment
Set different criteria for Manufacturing. For example:
 BATCH DETAILS
 MFR DATE
 TIRE SIZE
 CUSTOMER CODE

34.  Quick and error free entry of batch details, mfr date, tire
size, customer code.
 Ensures total integrity of collected data.
 Avoids piling up of data entry work for counter staff
 Stock verification made easy.
 Raw materials are available in Just in time(JIT).