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

ZZZZZ

ZZ

Waiting

1,2,3,4,5,6

Overproduction

1st

Unused Creativity

x

Quality Defects

Motion Inventory

De-Burring

Processes

Wastes in a manufacturing process

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?