Technifor, a division of the Gravotech Marking Group, has a longstanding background in component marking and traceability. In this Q&A session, the company highlights why parts marking is becoming an ever-increasing requirement in the manufacturing process.
Why is there a drive in industry to mark parts?
As a traceability solutions provider, Technifor knows that the drive for parts marking and component traceability can come from a number of sources, such as a demand from a customer with a new product introduction, or the need to improve traceability for quality control, and even an internal business demand to improve manufacturing efficiency.
One thing is certain in today's business environment, quality and cost can't be separated. The fact that companies are now producing parts for a lower cost does not negate the need for the highest quality. Manufacturing and service companies have to improve their traceability to match the increased quality levels so the focus should be component traceability not the marking of a code.
Where does part marking and traceability come from?
Everyone understands the 1D barcodes found on products in a shop or supermarket which are scanned at the till and recognised by the system. However, we all know what happens when the barcode is damaged or bent out of shape – it becomes unrecognisable and we wait for a price check.
Offering a more advanced solution, 2D data matrix codes are read horizontally and vertically, which allows a lot more data to fit in a much smaller area. This technology was originally developed by NASA for the space shuttle to provide fast acting traceable codes to reduce the paperwork required, which at the time was many times the weight of the shuttle itself.
NASA developed it based on an algorithm used for the 1970s Voyager spacecraft programme to decode the images that came back from space. Created by Reed–Solomon, the algorithm provides code error correction – 2D matrix coding has been around for a few decades – but its use has only become widespread in industry during the past 10 years or so.
I have seen QR codes on advertisements – what are they?
The QR (Quick Response) code is another example of 2D code. Developed in Japan in 1994 by a subsidiary of the Toyota group, QR codes have become popular in consumer advertising and packaging. The growth of smart phone technology has provided increased code reading access and now 2D codes have become a part of everyday life.
What advantages can the use of 2D code offer?
Because of the way the data matrix code has been developed it does not require the sharp black and white contrast of a standard barcode. The code can therefore be directly printed on to a part using laser or percussion marking technology, and the label, which can be peeled off or damaged, is no longer required and the part permanently marked for ‘life'.
The algorithm used means there is an error correction redundancy in the code, so up to 20% of the data matrix can be lost, but it will still read correctly so the part can be traced after years of service.
This will appeal to companies that offer extended guarantees such as automotive suppliers, that might have to trace parts as they go through the life cycle on a vehicle. A product recall situation is made far simpler because it can be retraced to a specific supplier. In terms of tracking parts back, rather than the scenario of a complete day's production to check through, it can be narrowed down to the specific day and time when a raw material or welding problem or even a paint issue occurred.
With the data matrix scanned in to a production control system the manufacturer will be able to access the necessary assembly information and potentially save a lot of time. Knowing where and when the problem originated from ultimately reduces the cost and improves efficiency.
Once the code has been applied how is it read?
Although many companies offer 2D code marking equipment, it is both the generation and reading of the code that is vital. With a code it is about capturing an image, and there are many opportunities for things to go wrong. Time is always limited in a production environment, so it is important to make sure the image of the code is robust. And, if there is a supply chain the supplier will need to ensure that the customer reads the code in the same way.
Readers come in two forms – handheld and fixed readers. Selection depends on the application and the traceability solutions provider should suggest which type is best based on specific needs. It must be stressed that with 2D codes you are not printing a code and analysing it – you are printing an image. There is a big difference so other factors have to be considered. A well printed code viewed under bad lighting will be hard to read so the lighting used must be considered as well. All of the various criteria have to be optimised, so it important to choose a supplier that has a proven track record of installing robust solutions.
How long does it take to test the equipment?
Successfully setting up the marking and reading can sometimes take a few hours to test fully and it is not a process that can be rushed. It is all about matching the solution to the production conditions and it takes skill, experience and an understanding of the matrix code.
Can my components be marked? Using laser or percussion marking equipment, most materials can be clearly marked. The actual matrix size will depend on the physical size of the component as well as the level of information required by the customer or end user. Most range between 5mm by 5mm up to 20mm by 20 mm and are generated by percussion or laser marking. As well as the 2D machine readable code, these marking systems can also generate human readable characters as well.
Information contained within the data matrix can come from a number of sources. For example, it can be sent from a central ERP system, created from a barcode on a job route card or even generated by the marking system's controller.
What will a traceability solution cost?
An entry-level 2D data matrix marking system can be purchased for around £4,000 but a reader will incur additional costs. However, most companies mark a part because they have been asked to, and marking parts adds cost. As marking is often associated with quality control, which is a customer expectation, the cost cannot be passed on. Although the investment required is not prohibitive; it might be a cost that has not been budgeted for.
Where and when in the production process should you mark?
Previously the trend was to mark parts at the end of the line but the more knowledgeable traceability solution providers are promoting component marking as early or as close to birth as possible.
The potential benefits of having live component data tracking through the whole process are significant and marking the part early provides this. It provides the ability to stop reject parts going through the process or, even worse, being sent out to customers. And, mixed or incorrect parts can stop a production line which can be very costly and is counterproductive for the supplier in terms of keeping a contract.
What should you look for from your solution provider?
If you have to invest in a traceability solution find a supplier that is happy to show you how beneficial it can be. It is fair to say a complete traceability system will not win you any business, but it could stop you from losing it!
And, it is not only beneficial from an engineer's point of view as the business development team can approach customers and demonstrate the robust nature of the parts tracking offered, providing a guarantee of product traceability and highlighting a willingness to invest in quality systems.
In today's competitive environment, manufacturers have to ensure they are always improving their cost-to-quality ratio –and full traceability supports this drive. It is vital to select a provider that offers a working partnership; one that will allow you full access and control of the system but will also provide a ‘walkthrough' to guide you to the right solution. Technifor's solutions are based on honesty and its ability to guide customers to the best option, which is why the company has built such strong, long lasting and understanding relationships with customers.
What about post investment support?
Technifor prides itself on the work it carries out for customers at its facility in Leamington Spa. A total of six service engineers are available to provide support and the sales team is also technically trained.
Through understanding customers' needs, the company is aware that a high value production line can't wait for three days for someone to come out and fix the problem. Its philosophy has always been to support customers in a strained or high pressured environment, with bespoke customer care packages. As a company, it offers traceability solutions, and its expertise means it can take full responsibility for the marking and reading of any data matrix.
Technifor
www.technifor.com
