Mitsubishi Electric, part of the Mitsubishi Group, was founded in 1955 with over 50 years experience in developing air conditioning systems. Mitsubishi Electric were the first in the industry to offer highly advanced ‘inverter driven’ systems. Inverter driven systems produce just the right amount of output to match the exact requirement of any building. These systems work so efficiently that they don’t waste valuable energy by over-heating or over-cooling, resulting in greatly reduced running costs.
Protecting the environment:
They only use chlorine-free refrigerants that are safe and have ‘zero ozone depletion potential’. Therefore their systems require less energy to run, and have lower indirect global warming potential too.
The Business Challenge
- Units are produced to fulfil orders and quotas. This information is stored in a database describing which assembly line, which model, how many etc, need to be made in a specific time frame
- A job card is produced for each unit that needs to be constructed. These are distributed to the correct assembly lines and then a unit is assembled to match the card. Each unit must have a Hanken Label attached, these were traditionally requested in batches on demand from management.
- A missing Hanken Label (or a replacement) would mean downtime in getting a replacement from the office.
- Any duplicate Hanken Labels into the production loop is disastrous for traceability and means the shutdown of an assembly line, or worse, the recall from the warehouse of a batch of finished units for retrieval of the ‘duplicate’ unit.
Solution
The production line has a PC connected to the database and wired up to a Zebra printer. A production worker scans a job card and the software looks at the database and locates the relevant serial number and automatically prints the Hanken label. Every label is recorded on the system, so if an operator attempts to scan the wrong item, an error message flashes and prevents the incorrect label being printed.
No interaction with the PC is needed the operator only needs to scan the bar code.
- The system makes the production of labels automatic
- There is no human interaction, no downtime.
- The system has overrides for needing reprints/replacement labels.
- No time wasted sifting through and matching stacks of Job Cards and Labels
- Job Cards are scanned by the system and the labels are created on demand
Further Additions to the Software
After initial deployment and it’s testing phase the software proved its reliability and was extended to also create ‘P-Labels’ alongside the Hanken Labels, these P-Labels are Rating Plate labels, generated with the same level of uniqueness and containing information exactly matching the produced unit.
Scanned Job Card
The setup for an Assembly Line consists of 1 Bar Code Scanner and 2 Zebra Printers connected to a PC running the software (with a network link to the production database).
The Bar Code Scanner is used to scan a Job Card, this bar code is sent to the software which queries the database and acts upon what it finds. These results are displayed on the monitor in a simplified way to make them visible and prominent in a factory environment.
A Job Card has been scanned (displayed in the middle of the screen) on Assembly Line ‘D’.
The centre of the screen remains green, this means that the Job Card scanned is valid for this line. The Zebra Printers will output a Hanken Label and a P-Label to match the Job Card. The top of the screen displays indicators showing how much media is in the Hanken and P-Label printers.
Job Card scanned twice
The software queries the database and finds the data valid, but crossed-referenced with the log reveals it to be a duplicate. The screen turns red and the system is blocked.
This system is based in an industrial setting and correctness is paramount. The only way a user can interact with it is by scanning a Job Card. Line Foremen and Supervisors carry a set of special ‘Admin’ bar codes which can be scanned to control the system. In this case the user would signal to his Foreman that he has a problem if the Foreman hasn’t already noticed the errored state on the monitor.
The Foreman can now fully control the situation.
Did the user mistakenly scan the same Job Card?
Did the user waste or misprint one of the Hanken/P-Labels?
The Foreman can scan the relevant bar code for the following paths:
- CANCEL - The scan was a mistake, ignore it, don’t produce labels and continue
- REPRINT HANKEN / P-LABEL - The user scanned twice for a replacement Label. A replacement label is printed and the system continues
- REPRINT BOTH - Both labels need replacing, the Foreman is satisfied that this is the case and both labels are reprinted, the system continues
Media Indicators
The media in the Hanken printer is running low unlike the P-Label printer. The ‘Amber’ condition means the Foreman soon needs to replace the media. This early warning system means that the line doesn’t have downtime when a printer suddenly runs out of media.
The media runs out
The P-Label media is exhausted and the system is halted until it is replaced. A Foreman has ‘Admin’ codes for replenishing both media stocks and also clearing the ‘Out of Media’ status when this has been done.
Benefits
- Eliminates errors
- Increased productivity
- Cost savings
- One point of access for management
- No need for Management to keep track of the production data in the database
- No need for Management to track which labels have been printed and distributed
- Increased time for management decisions
- The software produces log files of exactly what has been printed (and reprinted) along with Line information and Time/Date stamps for analysis
- Eliminates any possibility of duplicate labels into the production line
- The system can be extended and new features added
“In our experience of working with Barcode Data we have been supplied with a service which has totally satisfied our company’s needs.
Bar Code Data provided an open and friendly approach to business focused on our exact requirements and have produced effective solutions for our fast moving manufacturing environment.
From initial enquiry through project implantation to after sales service Bar Code Data have supplied an excellent service. We would have no hesitation in recommending or using Bar Code Data’s services again.”
Alan Keast
Mitsubishi Air Conditioning Systems Europe Ltd
Hardware Used
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Datalogic Dragon Scanners The Dragon is an ideal solution for any application requiring a high performance scanner designed to handle harsh environments. Ease of use and an affordable price make the Dragon a versatile solution. |
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Zebra ZM400 Printers Zebra’s best-in-class Z Series printers just got better! The ZM400 includes additional productivity-enhancing features and modern, flexible network connectivity for easy system integration in most manufacturing, warehousing and business applications. This industrial/commercial workhorse also delivers efficient 4-inch-wide labeling thanks to its quick throughput and 10 inches-per-second print speed. |
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Bar Code Data
Bar Code Data are a leading UK provider of specialist barcode and RFID solutions covering a range of products and services from all major Auto ID manufacturers.
Our technical expertise includes in-house design, label manufacture and bureau printing services backed by our commitment to providing outstanding value, quality and customer service to offer a one stop shop solution for all your automatic identification and data capture needs.
