Lot Control & Traceability

The IGear Lot Control and Traceability Applaication improves manufacturing quality by the correlating manufacturing data to an individual part or group of parts, allowing a manufacturer to better detect and correct problems.

The Problem

Quality is at risk when a manufacturer's ability to trace, isolate, contain, and correct problems in the manufacturing process is inhibited.  When essential data does not travel with the parts as they move through the manufacturing process, a manufacturer loses the ability to quickly and effectively analyze and respond to quality issues.  In addition, the opportunity for continous inprovement is limited.

The Solution

IGear’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 IGear software products, proven hardware devices, and best practices based on twenty years of plant floor integration experience in the automotive industry.

Lot Control

The IGear Lot Control and Traceability Application 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)

IGear 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 for operators and managers
• Replaces an error prone batch label printing process with an automated forced labeling system

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 IGear 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

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