How to use Track and Trace to Automate Production Management

How to Use Track and Trace to Improve Production Management (Top 6 Key Takeaways) Last Updated: November 2022 Hi everyone! I've been working hard to keep my company’s production line running smoothly. We’ve got great tech, solid processes, and talented people in place. But despite all that, we're still facing some challenges—quality control issues, inefficiency, and late deliveries. Why is this happening? It could be because we haven't fully embraced track and trace technology to maximize our business potential. In today’s automated production lines, track and trace has become a game-changer for manufacturers. New advancements in traceability automation let companies virtually map out the journey of products and components from manufacturer to end-user while tracking data throughout the product lifecycle. Thanks to innovations like MECCO’s new LightWriter™ laser marking workstation, traceability solutions are becoming more affordable and user-friendly. The main benefit? Visibility. Advanced part marking technology can help you gather information on every single component at every stage of the process. This data opens the door to continuous improvement and optimizing production. It’s all about the mark. However, this process doesn’t always go smoothly. If items aren’t properly marked, the right information doesn’t get communicated. Communication gaps lead to downtime and other inefficiencies that impact our processes and bottom line. Moreover, some manufacturing companies still rely on outdated strategies like manual record-keeping, which limits access to valuable data. In an age when digital technology drives the industry forward, this is a huge missed opportunity. MECCO and Rockwell Automation teamed up to share insights on how to integrate technology, communication, and data analysis effectively. Dave Sweet, our president here at MECCO, has over 30 years of experience in engineering, with about 15 of those dedicated to developing our expertise in smart marking and traceability solutions. Dave collaborated with James DeBano, a senior engineer in Rockwell Automation’s Information Solutions group, who designs and implements track and trace software solutions for manufacturers, backed by his experience in software engineering and data analytics. Together, these two experts presented a solution combining equipment and software engineering to help manufacturers answer the question: How can my plant thrive with track and trace technology? Here are the top five lessons from this insightful session.

Top Lessons for Automating Production Management with Track and Trace

1. **Let Go of Handwritten Record Keeping (and Other Outdated Processes).** This happens daily. A mistake in the manufacturing process leads to defective products due to the absence of an effective error-proofing system. The defective part reaches the customer, resulting in rework, recalls, or a tarnished reputation. How did this happen? Maybe there wasn’t a proper system to record the defect in a database. Instead, someone in production might have scribbled “Defective Part” on a piece of paper. That note probably fell off, and those parts ended up in the customer’s warehouse. Now we’re in trouble. Why did that product get sent to the customer? And what exactly is wrong with that part? Could it be a safety issue? This is serious. For many manufacturers, dealing with such adverse events sparks a frantic search for a traceability solution. After the dust settles, they tally their losses and start looking for a better way to mark and track parts. Of course, error proofing isn’t the only challenge manufacturers face. With markets and supply chains becoming increasingly complex, recalls and counterfeiting risks are rising. These disruptions test your processes, increase downtime, and push you to deliver high-quality products consistently.

The solution lies in track and trace within the Connected Enterprise—creating smarter manufacturing for better, faster decision-making.

The solution, as Dave pointed out, is track and trace within the Connected Enterprise—building smarter manufacturing to enable better, quicker decisions. 2. **Barcodes Are Just the Beginning When It Comes to Identification and Traceability.** Parts can be identified and tracked in various ways. Your first decision is what information to include, whether it’s lot number, manufacturing date, or something else. Next, decide how to mark that information on the part. Should you use labels or a direct part marking machine like a laser or pin marking equipment? Will it be human-readable or machine-readable? For successful Industrial Internet of Things (IIoT) traceability, serialization is crucial. The mark acts as a “license plate” that links the part to a database containing all the relevant details. Machine-readable 1D linear barcodes or 2D Data Matrix codes are the best ways to display this information because they offer better readability—at the point of origin, at every stage of the process, and for the lifetime of the part. Additionally, barcodes can hold more information. So, now you’re marking data in the form of a 1D or 2D barcode on your parts. You might even use machine vision to read that data and verify your marks. Many manufacturers think they can stop there. After all, if the part comes back, you can trace it to see when it was produced. But here’s why you shouldn’t stop there. **Smarter manufacturing opportunities emerge from marking at strategic points throughout your process and connecting that barcode to your enterprise.** This is when you can truly transform your business. “The future of manufacturing is increasingly about people actually utilizing track and trace—not only during the process or out in the field and back, but also within a Connected Enterprise,” Dave said. “Traceability is a process.” 3. **2D Barcodes Are the Better Choice for More Robust Data.** Walk through any grocery store, and you’ll see 1D barcodes on nearly every product. They work well when you only need to display a limited number of characters. However, as you add characters, the code must get longer and longer to fit those characters. That might suffice for a loaf of bread, but for manufacturers wanting to capture **more valuable data**, 1D barcodes just won’t cut it. Over the past 10 to 15 years, companies have shifted toward 2D codes. Unlike 1D barcodes, 2D codes can embed a significant amount of information in a limited space. There are two main types of 2D codes. A 2D Data Matrix holds about 2,335 alphanumeric characters, and a 2D QR code can hold around 4,296 characters. One of the biggest advantages of 2D codes for manufacturers is redundancy. If you damage the code, you’ll still be able to read it. When any part of a 1D barcode is destroyed, it becomes unreadable, and all that information is lost. What kind of information should you include in your 2D barcode? Dave recommends encoding only the most critical data. In other words, “you don’t need to put a whole book in the mark. There are some limitations there.” The ability to include more robust data is essential when it comes to meeting industry standards and regulations. We see permanent 2D codes widely used in industries like medical devices and automotive. For example, under the FDA’s Unique Device Identification (UDI) regulation, a GS1 Data Matrix can encode all necessary information even on the smallest devices. 4. **Adopt a Long-Term Approach to Part Marking for Better ROI.** In uncertain times and highly competitive markets, it’s tempting to opt for a cheaper upfront solution to track your parts. But when you look ahead to the next five, ten, or fifteen years, you may want to consider how these two factors influence your equipment investment: **Permanent vs. Non-Permanent** When it comes to part marking, there are two main approaches—permanent and non-permanent. Permanent marking methods, such as direct part marking (DPM) with a laser or pin marking machine, involve engraving characters, part numbers, logos, graphics, or barcodes directly onto the part’s surface. This type of mark is permanent. (Here’s a free download to help you understand how to choose the right marking technology for your application and material.) Permanent marks are essential for lifetime traceability. In the event of a product recall, parts would need to be traced back to the original manufacturer. That’s why many manufacturing regulations require companies to use permanent barcodes. Non-permanent marking methods include inks, tags, and labels. Keep in mind, though, that they often can’t withstand the usual wear and tear, especially in harsh environments like the oil and gas industry. **Hidden Expenses** While labels or ink may seem like the more cost-effective option compared to DPM, hidden costs add up quickly. For one, when a label falls off, it costs your company time and money to remark parts. Downtime is also a challenge when cleaning or unclogging a printer. Consumables are another major cost for ink or labels, ranging from $0.07 to $0.09 per mark. High-volume manufacturers can significantly reduce costs with permanent marking methods like laser marking, which only costs $0.02 per mark. Today, laser marking also requires fewer replacement parts. Dave explained that “15 years ago you would have to change a light bulb in the old flash lamp lasers. Now it’s all diode-based systems. So you’re talking hundreds of thousands of hours before those need to be replaced.” When you look at the long-term numbers, a DPM system is usually the most cost-effective and can help bring your processes into Industry 4.0. 5. **Ensure Your Marks Get a Passing Grade.** Did you know that many industry regulatory agencies have implemented mark grading scales? When it comes to traceability marks, quality really does matter. Readable marks ensure successful tracking through the manufacturing process and supply chain, and tracing back to its origins. The critical data contained in your mark is useless if the mark isn’t readable, scannable, and traceable. That’s why, once you know what marking method you’re using, the next step is reading and verifying those marks. Watch how the reading and verification system works. The robotic arm moves a part to be marked on one side by a fiber laser marker. Then, it rotates the part allowing a dot peen marker to mark the other side before moving the part in front of a camera for reading and verification. This process can be seen on the laptop computer as the marks receive a pass or fail grade. “A passing or failing grade is particularly important in the automotive and medical device industries,” said Dave. “We want a nice contrast so that code can be read, which is why we’re seeing a lot of manufacturers laser marking 2D barcodes because that allows them to get this high-quality mark.” To learn more, get in touch with our experts. We can recommend a phased track and trace solution based on your specific requirements.

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