Using Software and Automatic

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Using Software and Automatic Identification
Technologies For Error Proofing Success
By
John Piatek
Vice President of Technologies
Freedom Technologies Corporation
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Error Proofing Dilemma
So you are having labeling problems with your
customer?
You are not alone!
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AIAG Where do we see the most non conformances?

• Bar Code Labels are inaccurate
• Lack of Control of Work in Process
• Lack of Control of FIFO
• ASN is not Generated Automatically
• Inadequate Storage Location Labeling

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Labeling Error Proof Hit List

• Wrong Label on Container
• Wrong Parts in Container
• Wrong Side in Container (Left-Right)
• Wrong Color in Container
• Mixed Parts
• Missing Label
• Partial Container
• Wrong Destination
• Wrong Engineering Level
• Unreadable Labels
• Wrong Sequence
• Wrong Part ID
• Wrong Data in Barcode

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Keys to Error Proofing Processes

• Make Error Proofing Part of Advance Planning and
  PFEMA Development!
• All Inventory Serialized if possible
• Goal Remove Human Decisions
• Automated Reporting
• Automated Tracking and Accountability
• Real Time Data Collection with error Feedback
• Software Has Hard Stops Built In

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Direct Parts Marking Initiatives

• AIAG B 4 Part Label
• AIAG B 17 Direct Part Marking Guideline
• Tread Act Education
• GM 1737

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Direct Part Marking Part Identification

• Each part is marked with a bar code or symbol
• AIAG B4 provides detailed information for DPM
  content
• Options include, Part Number, Serial Number, DUNS
  Number, Date of Production, etc.
• All information is retained in a database
  including Lot Control Data

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Examples of Direct Part Marking Methods
Part Number Marking Methods
Perishable Tooling
Combustion Thermal Spray
Spray and Fuse
Serialized Marking Methods
Sticky Label
Ink Jet
Pin Mark or Laser
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Linear Bar Codes Vs.2D Bar Codes
2D symbology can hold large amounts of data by
carrying information in both horizontally and
vertically directions. Is really a mathematical
formula!
2D Symbology
Bar Code
Information
Information
Information
No information
Information
Information
Symbology Type
Bar Code
2D Symbology
Data Type
Alphanumeric, Binary
Alphanumeric
Data Capacity
Approx. 2,000 char.
Approx. 20 char.
Data Density
20 - 100
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Data Restoration
Yes
No
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Parts Marking Options

• Serialized Part Marking
• Laser DPM - 17K to 100K
• Ink Jet DPM - 17K to 30K
• Pin or Peen DPM - 6K to 20K
• Labels 3 to 30 cents each
• Non Serialized Part Marking
• All of above
• Perishable Tooling Free to 500
• Insert in Mold or Die Free to 500

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Part Mark Reading Options

• Laser Scanning - 300-3900
• Fixed Mount Cameras - 6000
• Handheld Imagers - 4000
• Coming Attractions600 - 3000

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Error Proofing Examples

• Injection Molding Serialized Barcode
• Injection Molding Base Part Barcode
• Stamping Serialized Barcode
• Stamping Base Part Barcode
• Extrusion Serialized
• Work in Process Serialized
• Re-Labeling Process Four Ways to Error Proof
• Others

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Injection Molding Serialized Barcode
Scrap Parts LH
Read Bar Code and Verify Clips Tape
Assembly LH Fixture
FG Container LH
Verify Color
Injection Molder
L
R
Read Bar Code and Verify Clips Tape

• Feed inlays
• Mold parts
• Apply Serialized Barcode Label
• Attach Clips Tape
• Auto Vision Test
• Visual inspect
• Scan Pack
• Container label

FG Container RH
Assembly RH Fixture
Verify Color
Scrap Parts RH
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Injection Molding Base Part Barcode in Mold
Scrap Parts LH
Read Bar Code and Verify Clips Tape
Light Tree
Assembly LH Fixture
FG Container LH
Verify Color
Injection Molder
L
Read Bar Code and Verify Clips Tape
R

• Feed inlays
• Mold Parts With Part Barcode (Left or Right Base
  Part )
• Attach Clips Tape
• Read Barcode Auto Vision Test
• Visual inspect
• Pass Light Tree Pack
• Container label

FG Container RH
Assembly RH Fixture
Verify Color
Light Tree
Scrap Parts RH
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Stamping Serialized Barcodes
Count Status Screen
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Current Count Container

• Introduce Material
• Verify Material
• Retain Lot Info
• Produce Part
• DPM w/ Serial No. and Part No. (AIAG B4 Std.)
• Scan Part to Container
• Earn a Label

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Stamping Base Part Barcode Inserts in Die
DPM Reader
Count Status Screen
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Current Count Container
2 Station Progressive Die
Verified
Left and Right Separation Chutes

• Introduce Material
• Produce PartStation 1
• DPM Part No Station 2
• Scan Part to Container
• Earn a Label

DPM Reader
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Extrusion Line Example
Enter Part
Enter Ship To
Set Up
Serial 1234
1.445 Green
Serial 1234
Serial 1234
Check for Status
Earn a Label
Mark Part
Pass All Processes?
Cut to Length
Read Barcode
Count To Container
Read Barcode
Check for Right Part
Duplicate Serial?
Feed Extrusion
Extrude
Read Color Value
Container Full!
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Work In Process
Direct Parts Marking
Device Interface
Scan to Report Production
Error Proofing Assembly Lines
Receive R/M
Start Traceability
Interfaces to all shop floor data devices,
including PLCs, Vision Systems, Scanners, Color
Sensors, etc.
Reports production/scrap on scan
Verifies that part is not already assigned to
another container
Verify part is correct for container
Creates Birthmark for each part
Each Good serial number read, increments box
count by one
MMOG The Organization shall have a process to
correctly ID all material, including in process
and DPM when needed
Verifies part is not on hold or reported as scrap
Verify all operations are complete and passed
Links quality tests to Serial and pass/fail
Earn-a-Label prints correct container label
automatically
Scan for Inventory Move
Scan for Count to Container
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Re Labeling
Scan to Create Shipping Label
Label Swapping
Customer Label
Customer Label
Direct Parts Mark
Prints Customer Label
Internal Label
Internal Label
Prints Customer Label
Verified!
Verified!
Correct Labeling!
Correct Labeling!
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Fuel Injector
Engine Block
Valves
Crankshaft
Metal Castings
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Some Other Benefits of Error Proofing
Scanning provides increased accuracy for
production reporting (no typing errors) Provides
information ability to automatically time study
manufacturing efficiencies Provides for
automatic cycle counting error proofing of each
transaction Enables Lot Traceability Links Raw
Materials to Finished Goods at the container
level Provides the current locations of
containers in the plant in real time Allows a
real time update of what is available to ship and
its location Verifies that correct customer
labels are applied to each tote as they are
packed for shipment Documents an audit trail of
each totes location, movement process,
disposition, quality tests, operation, operator
other historical information. Places product on
hold by serial number to prevent shipping non
conforming parts  Links raw material usage to
actual containers for lot traceability Retains
serial number with operator and machine
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Thank You!
John Piatek
Vice President of Technologies
Freedom Technologies Corporation