Coding systems for lean production

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?