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APPLICATION BRIEF

The challenge: managing the challenges o a global

marketplace and stringent regulations without impacting

quality, productivity, efciency and proftability

Discrete and process manuacturers in virtually every industry ace a common set o

challenges. Due to the globalization o the marketplace, manuacturers must now compete

with companies all around the world. The global marketplace in turn places even more

pressure on pricing and product quality. In addition, the development o government

and industry-imposed regulations add to the everyday administrative burden by requiring

‘cradle to grave’ product traceability to protect consumer saety. For example, in the U.S.,

the Prescription Drug Marketing Act (PDMA) in the pharmaceutical industry requires a

complete pedigree rom manuacturing to the store shel to prevent substandard and

countereit drugs rom entering the supply chain. The proposed HR2749 will increaseood traceability requirements to help ensure the saety o imported oods. The Produce

Traceability Initiative (PTI) is an industry-driven eort to achieve end-to-end traceability

or every case o produce by 2012. And the United States Department o Deense (DoD)

requires compliance with MIL-STD 130N, Item Unique Identifcation (IUID) standards that

provide unique identifers to better track and manage critical assets.

To remain competitive in this environment, manuacturers need to cut cost, time and

errors out o the end-to-end production cycle, yet still retain product quality and compliance

with government and industry regulations. However, manual procedures that require

inormation to be captured frst on paper and then entered into the computer actually

lengthen cycle times and increase the opportunity or data entry error. Mistakes can

occur when inormation is: initially written on a orm; transposed incorrectly due to

handwriting legibility issues; or keyed into the computer. In addition, the lag time between

when inormation is captured and when it is available in your system provides moreopportunity or error. For example, the use o a wrong part on the production line may

not be visible or a ull day, rippling into the high cost o re-work.

In addition, many regulations involve the storage o a large volume o data — such as lot

numbers and expiration dates. Manuacturers with 1D bar coding solutions in place today

may fnd that 2D bar codes are required to accommodate the additional inormation,

which in turn may require an upgrade rom laser to digital imaging scanners.

1 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

The Motorola DS3500 Series

Enable cost-eective quality control, error

proofng, work-in-process monitoring and

traceability in your manuacturing operations

utomate your processes to

mprove margins and better serve

our customers with Motorola’s

S3500 Series o rugged cordless

nd corded scanners. Built to thrive

the harsh environment o a

anuacturing plant, this versatile

mily can capture virtually any

ar code — 1D, 2D, high density

D, DPM or IUID codes — even i

e label is scratched, damaged or

rty. And our advanced scanning

chnology ensures frst-time

verytime accurate bar code

apture, improving productivity and

roughput and reducing errors on

e production line, in quality control,the warehouse and beyond.

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2 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

The solution: automate data

capture and error proo processes

with high perormance bar code

scanning at the point o work withthe Motorola DS3500 Series

Motorola’s exible DS3500 Series o rugged

handheld 2D imaging scanners helps enterprises

address these issues by enabling the automation

o practically any paper-based data capture system.

Both the DS3508 corded and DS3578 cordless

models can read virtually any type o bar code,

enabling the integration o whatever symbologies

are required — including 1D, 2D and IUID bar codes

as well as direct part marks (DPMs). With built-in

support or Item Unique Identifcation (IUID),

the DS3500 Series can validate, read, separateand transmit the right inormation or seamless

integration with your application. In addition, the

DS3500 Series can read virtually any type o DPM

code on any surace, including dot peen, laser etch,

chemical etch, inkjet, mold, cast and thermal spray

marks on metal, rubber, plastic or glass.

Now, inormation is automatically and accurately

captured and transmitted instantly into the right

business system, streamlining every inch o your

manuacturing plant — rom the warehouse to

the production line. ycle times are dramatically

reduced. Processes are error-prooed. And end-to-

end traceability data is captured cost-eectively atevery step in the production process. The result is

an improvement in the product quality, production

velocity, delivery turnaround times, customer

satisaction — and proft margins.

The applications

Throughout your manuacturing operations —

rom the plant oor to the warehouse and the

tool crib — the DS3500 Series:

• Enriches quality control on the production line

• Enables cost-eective ’cradle to grave’ traceability

• Error-proos the production process

• Improves process efciency through real-time

work-in-process (WIP) monitoring

• Streamlines inventory management

Real-time quality control

Regardless o whether you are manuacturing new

products or providing repair services, the DS3500

Series helps control quality by ensuring that product

enter and pass all quality checkpoints as wellas process consistency. As a product reaches a

checkpoint — rom a hydraulic pump that requires

pressure testing to a cam shat that requires a

dimensional check or a programmable component

that just received a sotware download — a quick

scan o the bar code can instantly capture the date

and quality station that conducted the action. The

result is the cost-eective collection o indisputable

business critical electronic documentation.

In addition, scanning can also provide direction

and veriy that all steps in a specifc process

were completed, providing personnel with the

most accurate inormation possible, ensuringthe consistency o the process itsel and

increasing accountability.

Real-time track and trace

The ability to scan raw materials and work in

process at every stage o production enables the

ast and cost-efcient collection o track and trace

data that helps protect the lives o consumers and

ensure compliance with a myriad o government

and industry regulations. Process and discrete

manuacturers alike can track the lot and batch

numbers o ingredients and parts as they move

through the production process and begin their

journey through the distribution channel to the

end customer — rom our used to make bread to

the processor in a computer to the sotware that

controls the transmission in a vehicle.

The resulting real-time track and trace data enables

very rapid, yet cost-eective recalls. Manuacturers

can identiy the location o all products that contain

the tainted ingredients or aulty components —

regardless o whether they are WIP on the production

line, waiting to be shipped to a distributor, en-route

to a distributor or customer, or already delivered to a

customer. The labor required to execute the recall is

minimized, yet all aected parties can be personallynotifed aster. The amount o product that must

be recalled is limited to only product that is actually

aected, eliminating the time, cost and lost revenue

associated with removing uncompromised inventory

rom the supply chain. And the agility to respond

rapidly protects consumer saety and helps minimize

the impact on brand equity.

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shipping o fnished product. The DS3578 models

can be wirelessly connected to any standard

Bluetooth-enabled device, allowing manuacturers

to easily extend the benefts o automated bar code

capture throughout the acility to streamline anderror-proo inventory management activities. For

example, the device can be wirelessly connected to

Motorola’s vehicle mounted mobile computers on

orklits and other material handling equipment, a P

via a dongle or directly to your back end systems via

a Wi-Fi access point.

In the warehouse

• Receiving. A quick scan enables instant and

automatic reconciliation o incoming shipments

with orders. Any errors are immediately visible,

enabling cross-docking to minimize processing

time. Inventory is visible in the inventory system

the moment it arrives:

 – protecting against a alse out o stock

situation that could result in one o the most

costly events in a manuacturing plant — the

unplanned shut down o the production line

 – enabling quality engineers to instantly begin

testing raw materials to minimize quarantine

times and help keep the production line moving

3 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

Real-time error proofng

Regardless o whether workers are handling

individual parts or creating sub-assemblies, a quick

scan can veriy that the right part is about to be

used at every assembly station. A complete producthistory that details all the parts utilized as well as

the identity o the specifc assemblers can be cost-

eectively compiled, providing proo positive that

products were built properly. Production exibility

is increased since multiple products can be reliably

produced on one assembly line. And major cost

savings result rom the ability to eliminate:

• The high cost o re-work arther down the

assembly line

• A dissatisfed customer who receives a

deective product

• The negative impact the delivery o less-

than-perect products has on your brand.

Real-time inventory management

The Bluetooth®-enabled DS3578 is ideal in the

warehouse, providing cordless reedom and

improving saety or workers who are managing

inventory — rom the receipt o raw goods to the

The versatile DS3500 Series can streamline and error-proof the end-to-end materials management process. With the corded

DS3508 tethered to a workstation, incoming shipments can be automatically reconciled and visible in inventory in seconds,

without any processing of paperwork. In put-away and replenishment, the cordless DS3578 can be wirelessly connected to a

vehicle mount computer on a forklift — and a split second press of the scan trigger can allow operators to verify that the right

material is about to be selected or stored on the right shelf.

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4 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

• Put-away. A scan o incoming shipments can

display the exact put-away location and the astest

route to that location on the screen o the V5090.

And a quick scan o the shel tag at the put-away

location allows workers to place materialsin the right location, ensuring availability.

• Replenishment. When materials are needed on

the production line, a scan o the bar code verifes

that the orklit operator has selected the right

items, preventing mistakes that could result in

the costly production o unusable product.

• Picking. When ulflling orders, a scan o the

bar code allows warehouse workers to veriy

that they are about to select the right item

beore it is picked, ensuring order accuracy.

• Shipping. Beore a worker places a shipment

in a truck or delivery, a scan o the boxes andpallets in an order provides a valuable double

check that the right items are being shipped

to the right person. Mis-ships are avoided,

eliminating the high cost o retrieving and

re-shipping the order, as well as missed

delivery dates and disappointed customers.

In the storeroom

The DS3500 Series enables manuacturers to easily

and cost-eectively track high value parts and tools

throughout their liecycle — as they are received,

utilized and returned. The resulting real-time parts

inventory enables timely re-ordering, ensuring parts

are available when needed. A quick scan o the bar

codes on both the employee badge and tool provides

a record o who last checked out or returned a tool.

Accountability is improved, reducing the chances o

loss and thet. And tools can be easily located, reducing

the need or buer stock, as well as the associated

capital purchasing and inventory carrying costs.

The technology:

the Motorola DS3500 Series

Motorola’s DS3500 Series o rugged handheld

scanners are built to thrive in the harsh environment

o a manuacturing plant, oering the perormance

your workers need to maximize productivity — and

the rugged design, easy management and low cost

application integration required to achieve a low tota

cost o ownership (T).

The DS3500 Series delivers blazing performance on virtually

any bar code — including 1D and 2D, DPM and IUID serialized

bar codes; damaged and poor quality codes; and even codes

buried under shrinkwrap. Designed for scanning in noisy

manufacturing environments, the DS3500 Series provides three types of feedback to indicate a successful scan —

visual, audio and tactile.

The DS3500 Series: Capture every type o bar code with this single fexible scanner amily

The DS3500 family includes six models, allowing manufacturers to standardize on a single device type regardless of data

capture needs, simplifying purchasing as well as everyday device management. The following chart provides an at-a-glance

look at the functionality of the various models.

Model Corded Cordless

Motorola’sMax Rugged

Specs. 1D/2D

2D HighDensityCodes IUID DPM

ImageCapture

DS3508-SR • • • •DS3508-HD • • • • •DS3508-DP • • • • • • •DS3578-SR • • •DS3578-HD • • • •DS3578-DP • • • • • •

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5 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

Superior scanning perormance

Your workers will experience blazing perormance

on virtually any bar code — including 1D and 2D,

DPM and IUID serialized bar codes as well as

damaged and poor quality codes. Exceptionalmotion tolerance combines with omni-directional

scanning, eliminating the need to pause between

scans or align bar code and scanner — and enabling

peak productivity in the high volume scan intensive

applications common in manuacturing plants. And

to accommodate the high noise level oten ound on

the plant oor, the DS3500 series oers visual, audio

and tactile eedback to indicate a successul scan.

The illumination o two large LED’s, the traditional

‘beep tone’ and a vibration in the handle all indicate

a successul decode.

Extraordinary rugged design

With Motorola’s maximum drop specifcation o 6.5 t.

(2 m) to concrete and IP65 sealing, you can count on

reliable operation despite the inevitable routine drops

and exposure to dust, grease and jetting water.

Easy to manage

Support or Motorola’s 123Scan2 onfguration

Utility and Remote Scanner Management (RSM)

technology dramatically reduces the time, cost

and logistical headaches associated with scanner

confguration and management. Set up and

customize your scanners with our complimentary

utility, 123Scan2. This powerul P-based sotware

tool oers two patent-pending industry frsts:

• The ability to automatically detect and establish

2-way communication with your scanners,

without scanning a bar code

• The ability to update frmware without losing

scanner settings — or scanner connectivity

nce your scanners are deployed, RSM enables day-

to-day remote, network-based device management

rom a central location.

Easy and cost-eective application integration

Built-in eatures allow enterprises and government

agencies to manipulate and ormat the data properly

beore it is sent to the host application, eliminating

the high cost o modiying existing applications.Robust Advanced Data Formatting (ADF) enables

the easy addition o static and dynamic prefxes and

sufxes — including dates as well as keystrokes

such as ‘tab’ or ‘enter’.

In addition, Motorola-specifc integrated IUID parsing

capability enables the DS3500 series to validate

a IUID bar code against MIL-STD-130N specifed

constructs, decode the data and pass concatenated

IUID data or user-defned felds o inormation rom

the bar code to the host application. The need to

upgrade legacy sotware systems is eliminated,

and feld upgradeable IUID construct tables provide

investment protection.

Summary

When you invest in the rugged DS3500 series, you

can count on an investment that can serve your

needs today and well into the uture. For example,

2D bar code scanning provides support or emerging

standards, such as the GS1 initiative in the ood

and beverage, consumer goods and healthcare

industries. Three capabilities work together to

maximize liecycle:

• The rugged design is built to last, despitethe demanding environment inside a

manuacturing plant.

• The device can literally capture every type

o bar code that is available today, including

1D and 2D codes printed on labels or as direct

part marks (DPMs) as well as IUID codes.

• The ability to easily upgrade the frmware

ensures support or new symbologies that

may surace in the uture.

For more inormation on how the DS3500 Series can beneft your manuacturing 

operations, please visit us on the Web at www.motorola.com/DS3578,

www.motorola.com/ds3508 or access our global contact directory at 

www.motorola.com/enterprisemobility/contactus 

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8 APPLIATIN BRIEF: The Motorola DS3500 Series — Manuacturing

www.motorola.com

Part number: AB-DS3500MFTG. Printed in USA 08/10. MTRLA, MT, MTRLA SLUTINS and the Stylized M Logo are trademarks or registered trademarks o

Motorola Trademark Holdings, LL and are used under license. All other trademarks are the property o their respective owners. ©2010 Motorola, Inc. All rights reserved.

For system, product or services availability and specifc inormation within your country, please contact your local Motorola ofce or Business Partner. Specifcations are

subject to change without notice.