Human error eliminated
December 1st 2003

Package coding management can eliminate coding errors in the essential data on which warehouse and logistics systems depend. Claricoms James Butcher explains Much creativity and investment has been made in warehouse logistics, and in particular in technologies such as barcode scanning and sortation or RFID, to enable automatic distribution centres and to ensure stock is rotated and directed according to product or product life quickly and efficiently. Especially in an automated depot or fulfilment factory, operation depends on the accuracy of coding data because that is ultimately what ensures that the right products are picked. What is often taken for granted is that the barcode data being scanned is itself correct, when this is all too often not the case. Imagine a scenario where a case of strawberry yoghurt is scanned, sorted and diverted to a store, but the contents of the case are actually raspberry yoghurts. It is assumed that the depot has over or under supplied in error there is no strawberry yoghurt on the shelf and the excess of raspberry product often goes unsold or into the discount bin. Rise in unsaleables This is not an unusual scenario. According to a wide range of industry groups, the Grocery Manufacturers of America and the Food Marketing Institute being the most prominent, unsaleables in the USA alone accounted for a total of 2.6 billion dollars in lost sales in 2002. This rate has risen steadily since 1996. What is more disturbing is that more than 20% of unsaleables were either products that were out of code or with the wrong code. Ensuring accurate package coding and barcoding at source is essential given the whole supply chain is dependent on them. If the problem is detected before despatch by the manufacturer this near miss will result in product waste, re-work and the probable failure to deliver on time. Once the product is despatched, the cost of the same coding error is much greater. A single incident can cost tens of thousands of pounds. Claricoms solution is to target the prime cause of coding mistakes human error by replacing the need for manual input on a day-to-day basis with an automated code-based approach. The Package Coding Management System provides network of coding, labelling and barcode reading equipment using data that is centrally managed and validated. For example, the operator, using a portable Scanpoint handheld barcode reader, scans the production schedule to select the product for manufacture. The operator is then prompted to scan the point of sale packaging or other essential documentation to confirm the selection and that it it is valid for the current product and packaging. The product coding rules are then retrieved from the product database to set up the database traceability codes automatically. Data need not be keyed in separately to each machine, thereby removing the potential for human error. Correct and consistent Because the correct data is transmitted to the coding and labelling equipment automatically, consistent information is ensured across the multiple layers of packaging including transit barcode packaging essential to effective distribution. Finally, on-line barcode reading equipment can be connected to the same CLARiNET network ensuring correct, legible barcodes throughout production. Claricom products are compatible with major brands of in-plant coding equipment including Domino, Imaje, Linx, Markem, Mectec, TEC, Videojet, Zebra and more, allowing manufacturers to select the most suitable equipment for the different parts of their operations and still retain centralised network control. The benefits of a PCMS extend to packaging inspection, to confirm the correct packaging for the correct product. With centralised network control of packaging barcode validation equipment, the set up of each job is barcode specific and is combined with correct set up of the package and equipment. Scanpoint handheld readers can be used at any point during production to allow periodic quality inspection and production of an audit log. The supply chain is dependent on accurate product and package coding, and the on-time delivery of product to depots and stores. Package Coding Management Systems at the point of manufacture remove manual operations, remove human error eliminate risk and ensure accuracy.

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