Coding systems are changing to better support lean manufacturing principles of minimizing waste. New coding technologies can reduce various types of waste like waiting time, defects, overproduction, and unnecessary processes. Examples show that digital coding solutions allow for quicker product changeovers, less downtime, fewer mistakes, and increased flexibility. These improvements help manufacturers respond faster to customers, improve quality, lower costs, and boost productivity by eliminating various causes of inefficiency. Evaluating one's current coding system and how new solutions could reduce waste throughout the production process may provide opportunities to gain benefits from leaner operations.

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?