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I/Gear
lot control & traceability |
The Problem |
| I/Gear’s Lot Control, Traceability & Forced Labeling solution improves manufacturing quality by tying manufacturing data to an individual part or group of parts, allowing a manufacturer to better detect and correct problems. |
Quality is at risk when a manufacturer’s ability to trace, isolate, contain, and correct problems in the manufacturing process is inhibited. When valuable data does not travel with parts as they move through the manufacturing process, a manufacturer loses the ability to quickly and effectively analyze and respond to quality issues. The opportunity for continuous improvement is also limited. |
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I/Gear’s Lot Control,
Traceability & Forced
Labeling solution
improves
quality and responsiveness with the ability
to quickly ascertain detailed part or lot
information relative to:
- Materials
- Sub-component lot numbers and quantities
- Manufacturing conditions (machine ID,
operator, cavity, die, tool change, etc.)
- Inspection results (leak test, flatness gauge,
X-ray, CMM, etc.)
- Change points (casting, trim shop,
machining, assembly)
- Shipping records (container label data)
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I/Gear advantages:
- Replaces a paper-based traveler system
with a more comprehensive and automated
solution
- Captures Change Point data as the part
moves from one process to the next
- Addresses tracking and reintroduction of
repaired parts
- Implements automated part counting and
machine interlocking to ensure FIFO and to
prevent mixed lots and operator bypass of
the data collection process
- Implements a web reporting system that
allows operators and managers the ability
to enter data and create reports
- Replaces an error prone batch label
printing process with an automated forced
labeling system
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The Solution |
| I/Gear’s approach to lot control and traceability is to tie a
unique serial number to each step and condition in the
manufacturing process. The result is a comprehensive
genealogy and traceability record for each part or lot
produced, and the assurance that each shipping container
has the correct quantity and shipping label. This functionality
is achieved with a blend of unique I/Gear software
products, proven hardware devices, and best practices based
on twenty years of plant floor integration experience in the
automotive industry. |
Reporting:
A report may be keyed off any type of information
collected during the manufacturing process
(i.e. reports based on machine ID, tool change, part
number, serial number, data range, operator, etc.). The
I/Gear web interface allows a user to enter criteria to
customize reports showing various data views and
levels of granularity.
Range Lot Control:
Range lot control captures a genealogy for a group
of parts shipped to the end customer. Each group of
parts has a unique serial number that links to a unique
lot number.
One-to-One Lot Control:
One-to-one lot control provides a complete genealogy
for each individual part. Each individual part has a
unique serial number that links to a unique lot number.
This functionality may require additional part marking
technology and hardware infrastructure for individual
part marking and tracking at each step in the process.
Forced Labeling:
The process of printing one label at time forced by an
automated quality test result and controlled by a PLC.
Product Features:
- Printers for traveler and shipping labels
- Wireless hardware for scanning and operator entry
- Hardware for part marking, machine data collection,
and forced label triggering
- Data transport software
- Web interface for configuration and reporting
- Notification services to send emails, pages, and text
messages for pre-configured alarms and events
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