RealTime - Spring 2008 - (Page 24)

of quality control to ensure that products were being sequenced according to customer requirements. The first inspection occurred at the end of the production line. Using a set of preprinted module and rack labels, an operator manually applied labels to each module and to the completed shipping container. At the second inspection, after the product left the warehouse another worker visually examined the sunroofs in the container and verified that they were in the correct rack position according to a sequence printout. The final quality control checkpoint occurred prior to shipment. Before the container was loaded onto the truck, the roofs were again checked against the ordered sequence. Even with multiple inspection points, errors could still occur. “It was a manual process that was high cost, high effort and prone to human error,” Thibideau said. “We needed a system that reduced the amount of labor and the potential of errors made during the proofing process. In addition, we needed a system that was independent of our existing labeling software and had availability 24/7. We couldn’t afford to stop production should our network or ERP system be unavailable.” Eliminating costly mistakes With the new system from Intermec and ToolWorx, only one auditor is needed for the quality assurance check, which takes place at the end of the production line. A number of automated tests are performed on each sunroof to ensure that it meets all quality standards. After successful testing, an approval bar code label is automatically printed and applied to the sunroof. Once a rack is filled with sunroofs, they are scanned in position order into the Intermec PM4i printer to validate their part number, color and sequence within the rack. If the validation is successful for all modules, a rack label is printed, allowing the sunroofs to be staged for shipment. “The Intermec PM4i printer has an integrated processor— complete with operating system and programming language— that enables the development of a fully independent solution,” said Ray Silvius, business analyst for Webasto. “Because the system is self-contained, production is not interrupted if our network or ERP system becomes unavailable. Ultimately, this component, combined with its industrial construction, reputation for durability and previous experience with Intermec, is why we chose the PM4i over competing products.” 24 realtime / 2008

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RealTime - Spring 2008 Contents View Intermec News Profile: Chris Johnston Miles Ahead Partner Profiles Raising the Roof Intermec 2008 Conferences Signed, Sealed, Delivered Keep It Flowing Alarmingly Effective Events Coda: Terminix

RealTime - Spring 2008

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