1. Coding systems for lean production: waste reduction, increasing flexibility and productivity Charles Randon, Senior Product Manager, Linx Printing Technologies

2. Coding systems for lean production Overview What is lean manufacturing The role of coding and marking in production How coding solutions are changing Where coding fits with lean manufacturing Real results from leaner coding Questions 2 3. Lean Manufacturing can make your company more competitive and more efficient Lean principles: Maximise value for customers Minimise waste Focus on value streams across a business, not individual products and departments Lean Benefits respond to changing customer demands higher quality lower costs faster throughput times 3 4. ZZ ZZ Z Z Z Waiting 1,2, 3,4, 5,6 Overproduction 1st Unused Creativity x Quality Defects Motion Inventory De-Burring Processes Wastes in a manufacturing process RUSH! Transportation 5. Lean principles link to Overall Equipment Effectiveness (OEE) OEE aims to reduce and/or eliminate Six Big Losses most common causes of efficiency loss in manufacturing Breakdowns Set up and adjustments Small Stops Reduced speed Start up rejects Production rejects These link to the wastes that lean manufacturing wants to minimise 6. Coding and marking in manufacturing Coding on primary and secondary packaging Why code? Legislation Customer requirements Traceability Product identification 7. Whats your view on coding? Bottleneck on the line? Causes rework? Needs frequent maintenance? Long set up and change over times? Necessary but doesnt add value? Waiting time, defects, transportation, over-production 8. Coding technology is changing Reducing waiting time Maintenance: less frequent, less downtime Longer intervals between scheduled maintenance Quicker, easier maintenance procedures Self maintenance, mistake proof consumables changes, wash down designs Product changeovers: quicker, fewer mistakes Fixed analogue to variable digital coding technology from hardware changes to the press of a button Increased memory storage Multiple line settings as well as code content in memory Increased mobility 9. Coding technology is changing Reducing defects Code content: more mistake proof, more intuitive Simple code creation and editing Touch screen user interfaces On-screen help copying code content and set up between coders using USB Limited editing for individual users Automated code selection and editing Barcode scanner linked to coding equipment Links to PLCs PC control from web server to integration with IT systems 10. Coding technology is changing Reducing processes and over- production Less need to fit processes around coding equipment Minimal start up procedures, no need to leave powered or run every day One coder for several applications less variation, inventory Coding from any direction less product handling Mobile coding no need to have coders plumbed in 11. Real life examples R Ceravolo - fruit and vegetable packing Move from labelling to digital coding Extra process removed coding in line Faster throughput (from 300 to 1000 units/day) Next Gen Pet Foods Product changeovers quicker by using coding to apply more data to the pack Reduced pack inventory more generic packaging Output doubled Added value in being able to run on-pack promotions 12. Real life examples Twinings Tea Move from mask laser to scribing laser No need to change masks Less waiting time Wet Fix - bottled water More consistent print, fewer manual quality checks Less daily printhead maintenance Use one printer on several lines Fewer defects, less waiting time 13. Real life examples Pharmaceutical contract packaging Several printers connected to one PC Less set up time for each batch Codes controlled by one manager Less waiting time, fewer defects, and more management information Dried foods packaging Printers are mobile and interchangeable Use one printer on several lines, with fast changeover Less waiting time, less transportation (and less purchase cost!) 14. Tips for coding solution evaluation Run a trial Make sure the coding equipment really does eliminate waste Dont just look at the coder in isolation Look at how it can help eliminate waste in the whole production process Ask your supplier about real lean examples Benefit from their experience New coding equipment can pay back very quickly Look at total costs of ownership 15. Summary Lean manufacturing maximises value and minimises waste Coding solutions have changed to support lean principles Reduced waste: less waiting time, fewer defects, less over-production, fewer processes Coding solutions can help you to get leaner: respond more quickly to changing customer demands achieve higher quality reduce costs Increase productivity 16. Take a fresh look at your coding solution! 17. Thank you Any questions?