Coding systems for lean production: waste reduction, increasing flexibility and productivity Charles Randon, Senior Product Manager, Linx Printing Technologies
Sep 12, 2014
Coding systems for lean production: waste reduction, increasing flexibility and productivity
Charles Randon, Senior Product Manager, Linx Printing Technologies
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
Lean Manufacturing can make your companymore 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
ZZZZZZZ
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
Lean principles link to OverallEquipment 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
Coding and marking in manufacturing
• “Coding” on primary and secondary packaging
• Why code?– Legislation
– Customer requirements
– Traceability
– Product identification
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
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
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
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”
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
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
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!)
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
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
Take a fresh look at your coding solution!
Thank you
Any questions?