Batch, Label, Production

Confirmations in Shop
Floor
 What SF operators need to
scan?
Operator needs something to scan to generate labels,
confirm production:
Option 1: Order Number (unique, but need to distribute
paperwork)
Option 2: Work center (fixed, but not one-to-one relation)

With Option 2, still need to know the Order, so Option 1

seems preferred.

Additional challenges with Option 1:

How to make sure they are not scanning wrong order? Some form of
validation.
Some operators are working on multiple orders at the same time;
how to mistake-proof each transaction?
 Proposal
Plant supervisor:
Reserves batches for each order scheduled for the day (Z-
program)
Prints a sample Case label for each order (has barcodes for
material, batch, order number)
Hands label to each operator.
Operator
Operator verifies material matches what the line is set up
for
uses master label to produce labels in real-time (time-
stamp); attaches to cases
Builds a cube and confirms production by scanning the
case label for material, batch, confirm qty
 Printing case label: real-
world
Is it too cumbersome to invoke a command for each case label? Would
a user get confused with multiple printers with multiple lines?
Is pre-printing off the table?
This is only possible with one batch number per shift; to get extreme you could
have pre-printed case labels and cube labels. No RF guns needed in mfg area.
Less zebra printers; central located. Save money; less maintenance; less
training.
Would not have mfg time on label, but would have date and a case number
(similar to todays number written on the box) so still could maintain quality
tracking.
Could have the planned order number on the label to scan which would help
maximize backflushing against correct material.
Drawback: messy with creating a labels and distributing to floor,
Pro: If zebra goes down on line/ out of paper.have to react fastzebra in office
you have time or even a back-up; minimizes creating wrong label; minimizes
mistake of receiving in wrong product; reduced hardware and RF devices.
 What is a new FG batch
number?
Does FG Batch need to change w/ every change of film, bead,
shift
Is this too much overhead system work? The system can handle it.
Is Dart committed to the work?
The new batch number is user invoked. Too much room for error?
What if the change it not processed in SAP?
How will the line operator know to receive in a different batch? Read
each label for a different batch?
Why not one batch per shift?
Less overhead work.
Can be systematic (time) defined.
Line operator does not have to know of different batches.
Drawback: broader tracking of component that went into product. Is
the risk of a larger recall batch worth the savings gained through
operating efficiency and ease of understanding?
 RM Staging
Bead, Carton brought in by material handler
(WH function)
Does Ink, Film also handled by material
handler?
When handler brings Ink, film to the floor, need to
scan location to confirm putaway in a specific
location
System continues to backfush in FIFO approach
Still retain traceability without batch change
Change in film does not trigger new FG batch.
Less overhead work.
 Batch where-used list
One FG batch linked to multiple RM batches;
batch 0000001314 derived from RM batches
0000000931, 0000001311.