Delphi Common Approach To
Label Error Proofing
2/28/00
1
Label Error Proofing
Common Approach
Contents
? General
–
–
–
Information
Introduction
Application
Types of Label Errors
? Best Practices
– Non-Technical Solutions
– Technical Solutions
»
–
Solutions & Examples
Advanced Technical Solutions
? Appendix
– Labeling Process Gap Assessment Definition
– Labeling Process Gap Assessment Evaluation Criteria
– Labeling Process Gap Assessment Tracking Form
– Label Best Practice Look Across Sheet Example
– Additional Labeling Error Proofing Best Practice Examples
– References
2
General Information
3
Label Error Proofing
Introduction - I.D. Technology
? The
Goal is to achieve zero label errors
? This approach builds on the Delphi Common Procedure
Requirements for Product and Shipping Labeling
? It is important to complete all procedures, training and other
non-technical actions before attempting technical solutions
? Manufacturing systems will need an identification
technology solution to achieve and sustain zero label errors
? There are several Part Identification Technologies:
–
–
–
–
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Bar Code Scanning
Vision System
Colorimetry
Optical Eye
Fixtures and Tooling
4
Label Error Proofing
Application - I.D. Technology
? Conditions
where I.D. technology should be considered as
a solution:
–
–
–
PFMEA RPN number indicates unacceptable risk
Any area where multiple parts/multiple labels are available to be mixed
» Fabrication or assembly areas
» Multiple process streams
» Pack stations
» Shipping areas
Variable label data
» Destination code
» Serial number
» Lot tracking number
» etc…..
5
Label Errors
? Mixed
parts - Different part numbers are mixed within a
container that has been identified as containing only one
part number.
? Incorrect Label on Individual Containers - Parts shipped
in cartons within a master pack have the wrong label on
one or more of the small cartons.
? Mis-sequenced Container - Sequence in the container is
not correct.
? Unable to Read Bar Code Label - Bar code quality does
not meet specifications.
6
Label Errors
? Wrong
Quantity on Label - Quantity referenced on label is
not the quantity in the container.
? Missing Part Label - A required part label is missing.
? Missing Shipping Label - One or more of the shipping
labels for a container, basket, a pallet, or master pack is
missing.
? Multiple or Duplicate Serial Numbers - one shipping
container has two or more shipping labels with different
serial numbers or two different labels with the same serial
number.
? Incorrect Part Label - The individual label on part is
incorrect.
? Incorrect Shipping Label - Shipping label does not identify
the parts in the container.
7
Label Errors
? Mixed
Containers - Two or more part numbers on a “master
pack”, skid, pallet, etc. when all cartons should have been
the same part number.
? Missing or Incorrect Information on Label - Occurrence
where any required information, including customer specific
information, is missing or is incorrect.
8
Best Practices
9
Label Error Proofing
Best Practice Questions
? Manufacturing
Process
– Is container labeling part of the natural production flow process flow?
– Is there a written labeling procedure which documents all activities related
to labeling a part and/or container?
– Are only properly labeled containers moved or stored?
– Is there a procedure for changeover?
– Is there a procedure for special runs (e.g. pilots, service)?
– Is there a procedure for partial containers?
– Can partials be eliminated? (build only to standard pack?)
– Is there a procedure for repair/scrap parts?
– Is there a procedure for removing old tags?
– Is label printer located at station where label is applied?
– Are labels printed on demand and applied immediately to part or
container?
– Can a label be used as a build manifest?
– How early in the process is the label applied?
– Does the operator who packs the container also attach the shipping label?
10
Label Error Proofing
Best Practices
? Production
of labels is a manufacturing process and subject
to all manufacturing quality procedures.
? Process to notify site manufacturing engineering of new or
revised labels documented in the site work instructions.
? Methods for obtaining label content and verification of labels
documented in the site work instructions.
? Label design(s) complete and released before production.
? Label design compatible with Mfg. process and equipment.
? Use Label Process Readiness Checklist
? Label stock, ribbon, information content and location treated
like product components and are subject to change
management procedures.
? Labeling inventories are controlled and the co-mingling of
labels is prohibited.
11
Label Error Proofing
Best Practices
? Labeling
processes included in the PFMEA performed
during Concept Development and Final Approval stage exit
reviews for new products or processes.
? Labeling equipment capable of meeting process quality and
rate requirements.
? Service and parts support available for labeling equipment.
? PFMEA reviewed with every label or label process change.
? Content and quality of all labels verified to meet
specifications and drawing requirements as a function of
first part verification.
? Process specifications and operator work instructions for all
labeling activities complete and documented.
? Operator work instructions include labeling requirements
and are visible and accessible.
12
Label Error Proofing
Best Practices
? For
products with unique software or calibration, the
programmer triggers printing and application of the label.
? Print on demand labels applied immediately after printing.
? Only known good parts labeled unless a factory information
system is used to track serialized products and prevent bad
products from being packed.
? For manual labeling processes, a “Running Now Display”
clearly indicates to operators which product is currently in
production.
? Rejected parts segregated.
? Operator displays large enough and conveniently placed for
easy viewing.
? Aids in place to help operator correctly identify parts.
? Aids in place to help operator correctly apply labels.
13
Label Error Proofing
Best Practices
? Products
have labels that can be machine read. (order of
preference - Code 3 of 9, Code 128, Data Matrix)
? All Customer required part labels scanned at pack out.
? Packing system prevents packing bad products.
? Packing system only allows packing products indicated on
shipping label.
? No manual data entry for printing labels or provide
independent second party verification.
? Mixed labels not available to operator.
? Dual scanning verification in place to ensure matching
shipping labels for dual ” shipping label requirements.
? System prevents duplicate container labels.
14
Label Error Proofing
Best Practices
? Verification
in place for non scan-able shipping label content
(e.g. DLOC for NAO customers) and quality.
? If over-labeling is required for shipping labels, verification in
place to ensure correct shipping labels applied.
? Old shipping labels removed from reusable totes, boxes,
skids, etc.
? No partial shipping containers stored within packing
operator’s reach.
? Partial bins stored in a designated area with a specific
location for each part.
? Error-proofing in place to prevent defective parts re-entering
the main stream from a repair loop.
? Shipping process verifies "container OK to ship" (I.e. has
been through pack out error proofing).
15
Label Error Proofing
Best Practices
? Verification
in place to ensure proper pallet labels, carrier
stickers or other shipping documents are accurate, present
and correctly applied. (matches EDI transmission).
? Preventive maintenance and repair procedures documented
and followed.
? Spare parts for all labeling equipment shall be identified and
available.
? Training defined, established, documented and verified for
operators, supervisors, maintenance personnel and
engineering personnel.
? Software development not performed on production
equipment. If absolutely necessary to do software
development on production equipment, removable media
such as a zip drive used. Complete first time verification
after using production equipment for software development
is required.
16
Label Error Proofing
Best Practices
? Unreleased
labels not permitted for use in production.
? Check label formats periodically for dedicated printers.
? For manually unloaded test fixtures where product labels
are applied, lock product into fixture until testing complete,
until passed and label verified correct and correctly placed.
? Operators prevented from making "good vs. bad" decisions.
? Verify "the right label - on the right part - in the properly
labeled container - on a properly labeled skid
? When a FIS is used to maintain data integrity, the material
path from the last test to pack and ship is access controlled.
? Printed label content and quality verified after any changes
are made to printing equipment.
17
Label Error Proofing
Best Practices
? Operator
work instructions include instructions for reporting
failed label scans to supervision and clearly forbid
repeatedly scanning failed labels to get a “good” scan.
? Quality of customer required print on demand labels
verified at least twice a shift. The quality of first and last
batch printed labels verified. The quality check shall include
machine verification of all printed scan-able symbols - bar
codes and 2D symbols.
? The Label Process Readiness Worksheet used as an
ongoing audit tool to verify required practices for labeling
processes are being followed.
? On-going independent process audits performed by the
Quality Manager or designee to verify compliance to the
latest site work instructions, process specs, operator work
instructions and maintenance procedures.
18
Label Error Proofing
Best Practices
? Any
products removed from packed, labeled boxes, are
verified to be labeled and replaced or the box is properly relabeled.
? Any containers removed from packed, labeled pallets are
verified to be labeled correctly and replaced or the pallet is
properly re-labeled.
19
Label Error Proofing
Best Practices
? Visual Controls
– Identify each part individually.
– Parts identified as early as possible in the process with the final
assembly part number
– Visual aids available to assist the operator responsible for labeling to
correctly identify the part.
– Sample boards or other visual aids easily visible at labeling location.
– Where multiple preprinted labels are necessary, only those in use are
available and all other labels are stored away.
– Where preprinted labels are necessary, a preprinted label inventory is
maintained.
– Color coding is used to differentiate similar parts so that the correct label
is applied.
20
Label Error Proofing
Questions To Ask On Labeling Process
? People
Focused Practices
– What type of variation in methods is evident?
» operator to operator?
» shift to shift?
» part to part?
» location to location?
– Is everything in place to aid the operator in following the procedures?
– Is there a training procedure for labeling operators?
– Are all labeling operators trained in the same method of labeling?
– Is there a verification that training has been satisfactorily completed?
21
Label Error Proofing
Questions To Ask On Labeling Process
? Error-proofing
– Self Verification
» Is there one consistent method for the labeling operators to self check?
? check
part number on part to label?
? check
part to sample board?
» Does the labeling operator have all the tools necessary to make the
correct label choice?
» Does the process allow part identification based on a part
characteristic?
– Successive Verification
» Are the labels verified by a different individual?
» Are the procedures in place for successive verification consistently
followed?
» Can shipping container be weighed to verify correct quantity on label?
22
Non-Technical Best Practices
23
Non Technical Practices To
Reduce Labeling Errors
? Write
procedure for all processes and instruct everyone on
procedures.
–
Perform audits to insure everyone is following the designated procedures.
? Have
second party verification and sign-off on all labeling at
the ship point.
? Create visual controls to make everyone familiar with
changeover procedure.
? Place strict controls on pre-printed labels.
–
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Lock up labels not currently in use.
Prohibit excess labels from being in labeling areas.
? Create
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“Running Now” visual controls.
Visual controls should display information on current part number running.
24
Non Technical Practices To
Reduce Labeling Errors
? Eliminate
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Promptly close, label, and remove partial bins at changeover.
Store partial bins in a designated area.
? Strive
–
partial bins.
to eliminate repairing non-conforming assemblies.
100% verify all parts re-entering regular loop to verify repair part to parts
running now
? Weigh
count shipping containers for correct count or correct
type.
25
Label Error Proofing
Non-Technical Lessons Learned
Wrong Option Content
Bar Code Applied Early in Process
Wrong option installed on doors throughout the assembly process.
Applying part labels with build instructions onto the door early
in the process allows assembly operators to verify the correct
option content.
Delphi-I
26
Label Error Proofing
Non-Technical Lessons Learned
Mixed Stock
“Parking Ticket”, Special Storage Dunnage for Rack, Pinion
Assembly Area
When an overbuild occurred, the partial container would be tagged and placed in a storage
area until that particular model was scheduled again. No other measures were taken to
insure accountability of mix or contamination.
• When an overbuild occurs, a bar coded “parking ticket” is assigned to that container.
• There is only one parking ticket available for each model.
• The bar coded parking ticket is scanned and information is stored in the Automatic Move
Order Database.
• Special color coded dunnage is placed over the partial and only one set is available for
each model.
• Container is moved to a storage area only large enough for one container of each model.
• When the container is reintroduced at assembly packing, the parking ticket is scanned to
guarantee a match with the information that it left with (tare weight, piece count, etc.).
Delphi-S
27
Label Error Proofing
Non-Technical Lessons Learned
Incorrect Shipping Label as a result of manual entry
Double Blind Data Entry System; 2nd party verification
The first inspection operator entered the part number and broadcast code into the
computer. If these cross-checked, a shipping label was printed and put on the
shipping container. After performing a quality audit, the second inspection operator
visually checked the label information and released the pack to the bander.
A “double blind” data entry systems is used. where both inspection operators enter
the correct part number independently. The first inspection operator enters the part
number and broadcast code into the computer. If the part number and broadcast
code cross-check, a small bar-coded label with the pack serial number is printed out
and placed on the pack. The second inspection operator performs a quality audit,
enters the part number on a second terminal, and scans the bar coded serial
number label. If the part number that the second inspection operator enters
matches the part number of the next label in the queue, a final shipping label is
printed. The second inspection operator places the shipping label on the pack and
releases the pack to the bander. If the information does not match a label is not
generated and the container is rejected. This container must then be trucked back
to the front of the conveyor and the process is repeated.
Delphi-C
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Technical Solutions
29
Label Error Proofing
Technical Solutions
? The
ID technical solutions include various levels of complexity
with two different technologies - Barcode and Vision technology.
The appropriate solution should be chosen based on the
manufacturing system needs and the requirement to achieve
and sustain zero label errors.
? Auto apply/verify bar code quality
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Verify part label to ship label
Verify part label and print ship label on demand
Print/apply part and shipping labels on demand
Verify part label to shipping label and sequence
Verify build process to part label
Serialized part labels to provide traceability
Integrated error proofing with PC&L to enhance traceability
? The
following pages provide definitions and examples of the
application of these technical solutions.
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Label Error Proofing
Technical Solutions
? Verify
bar code quality
– 1. Print bar code label (shipping or part) on printer
– 2. Verifier verifies bar code quality
– 3. Audio or visual signal returned to verify quality
? Necessary
Technology
– 1 label printer with label verification device included
1, 2
3
31
Label Error Proofing
Technical Solutions
? Verify part label to ship label
– 1. Scan set-up card into error-proofing intelligence system
– 2. Scan part label for part or container of parts to be packed into shipping
container
– 3. Scan shipping container AIAG label to verify it is correct
– 4. Communication to operator that labels are correct (communication may
include audio or visual signals or printed verification)
– Necessary Technology
–
–
1 base error proofing intelligence system
1 handheld scanner
Set-Up Card
1
4
Part Label
3
Shipping Label
2
32
Label Error Proofing
Example: Verify Part Label to Ship Label
Scan Kan Ban card to
create buckhorn labels
Key features:
Container labels & Kan Ban
cards linked to ship label.
Verify verification of
Kan Ban card and
buckhorn labels
Part number and
Quantity ticket
generated
Part number and
Quantity ticket scanned
to generate ship label
Ship labels & one
buckhorn label scanned
to link with Kan Ban
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Label Error Proofing
Example: Verify Part Label to Ship Label
Key features:
Ensures right parts in container along with right bar
coded shipping label by use of laser data terminal and
portable thermal printer to generate a final “QC
Inspected-OK to Ship” label.
Generates label with date, time, serial number that
matches ship label along with initials of operator who
did check.
Allows you to use multiple bar code symbologies,
database process scans and set up cross reference
tables for Delphi/Customer part number references.
Equipment: Symbol 3805 Data Terminal and Eltron
Portable Printer
Scan bar code part number
from finished parts in container
to be shipped
Scan bar code shipping
label assigned to finished
parts container
If part
scans match then
operator prompted to
scan serial number
from AIAG shipping
label
NO
If part #’s do not match
data terminal prints error
message to re-scan labels
YES
Scan bar code shipping
label serial number
“Q.C. INSPECTED - O.K. TO
SHIP” label is generated from
portable thermal printer
34
Label Error Proofing
Technical Solutions
? Verify
–
–
–
–
–
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–
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unlabeled part to ship label
1. Scan set up card or build book example for part configuration.
2. Utilize product characteristic to electronically identify part.
(e.g. color detection, gaging, product morphology etc.)
3. Scan shipping container AIAG label.
4. Communication to operator that labels are correct (communication
may include audio or visual signals or printed verification)
Necessary Technology
1 base error proofing intelligence system
1 handheld scanner
product sensing device 2
Set-Up Card
or build book1
4
1
3
3W Sw Cover LT
2
32
35
Label Error Proofing
Technical Solutions
? Verify
part label and print ship label on demand
– 1. Scan set-up card into error-proofing intelligence system
– 2. Scan part label for part or container of parts to be packed into shipping
container
– 3. Print shipping label corresponding to part label on demand
– 4. Apply shipping label to shipping container
– 5. May scan shipping label to verify part label to shipping label
? Necessary Technology
– 1 base error proofing intelligence system
– 1 handheld scanner
– 1 printer
Set-Up
Card
Part Label
1
3
4
5
Shipping Label
2
36
Label Error Proofing Example:
Verify Part Label & Print Ship Label On Demand
Compressors
pallet is built
at the end of
the line
Key features:
Ensures shipping label matches the
product label by scanning product
labels and on demand printing labels.
Security Access to the printing system
by sliding the operator ID badge
through electronic reader.
Operator scans ID
badge to access
into the printing
system
Operator scans
product barcode
label
System prints the
shipping label for
the scanned PN
with the Database
information
No
Database holds
the information
for each PN
System asks
the operator
if label legible?
Yes
Operator scans the
printed label to
verify printing and
store information
into Database8
Label infromation
is stored for future
tracking reports
37
Label Error Proofing Example:
Verify Part Label & Print Ship Label On Demand
Scan scanning
sheet
Key features:
Ensures correct label on the
product, correct quantity in
the pack, and the correct label
on the pack
A
Scan part
label
Label
matches scan
sheet?
No
Signal invalid
part error
Yes
No
Duplicate
part?
Signal
duplicate part
error
Yes
No
Pack item
count =
Quantity?
Yes
Signal Basket
Full
Print shipping
label
A
38
Label Error Proofing
Technical Solutions
? Print/apply
part and shipping labels on demand
– 1. Scan set-up card into error proofing intelligence system
–
–
–
–
–
?
2.
3.
4.
5.
6.
Part label is printed on demand
Part label is manually or automatically applied
Shipping label is printed on demand
Shipping label is manually applied to shipping container
May scan part label and shipping label for verification
Necessary Technology
–
–
–
–
1 base error proofing intelligence system
1 label application device (if label automatically applied)
1 handheld scanner
2 printers
4
Set-Up Card
5
Part Label
1 Shipping Label
3
2
39
Label Error Proofing
Example: Print Part & Ship Labels On Demand
Key features:
Senses correct part.
Prints & scans part label.
Counts & packs tray &
generates pull card.
Scans pull cards to generate
ship label.
Senses LH/RH
Prints Part Label
Label
Scanned
No Match
Hold
Match
Pull card generated
Pull card scanned
to generate ship
label
40
Label Error Proofing
Technical Solutions
? Verify
Part Label To Ship Label and Sequence
Download EDI customer schedule
2. Part label is printed on demand
3. Part label is applied (can be automatic or manual)
4. Part label is scanned by a fixed scanner to verify sequence
5. Shipping label is printed on demand
6. Shipping label is manually applied to shipping container
7. Shipping label may be scanned to verify
– 1.
–
–
–
–
–
–
?
Necessary Technology
–
–
–
–
–
Communication technology to facilitate downloading information from mainframe
1 base error proofing intelligence system
3
1 label application device (if label automatically applied)
1 handheld scanner and 1 fixed scanner
2 printers
4
2
7
1
6
5
41
Label Error Proofing Example:
Verify Part Label To Ship Label & Sequence
EDI seq.
from assy
plant
Key features:
Ensures correct label on the
product, product in the
correct sequence and aids
packing in the correct pack
Process EDI
transactions
Build product
based on run
sheet
Relational
database
Print daily batch of
product & ship
labels + run sheets
in sequence
Scan pack
label at pack
station
Scan & verify
unit to pack for
sequence
Scan seq.
label to verify
sequence #
Update
system seq# built
Graphic display
position in pack
42
Label Error Proofing
Technical Solutions
? Part
–
–
–
–
–
–
–
–
?
Label Used To Drive Manufacturing Process
2. Part label is printed on demand at the earliest possible point
3. Part label is applied (manually or automatically) to the basic shell of the part
4. Label is scanned by a fixed scanner to determine the part number to be built
5. Part is assembled according to the label
Error proof packing system prevents packing defective product.
6. Shipping label is printed on demand
7. Shipping label is manually applied to shipping container
8. May scan shipping label to verify it to the part label
Necessary Technology
– 1 base error proofing computer 1 label application device (if label automatically applied)
– 1 handheld scanner and 1 fixed scanner
– 2 printers
7
6
8
3
1
2
5
4
43
Label Error Proofing Example:
Part Label Used To Drive Manufacturing Process
Print daily batch
of product & ship
labels + run sheets
in sequence
Key features:
Ensures the right model is built
based on the run-sheet (temporary
label) placed in the fixture
up-stream in the assembly process
Customer EDI is
sent with requested
building sequence
Place sequential
run sheet in fixture
System scans
run sheets from
fixtures at critical
stations
Indicate
appropriate
component
to
component
to use
Assemble
component
Operator scans
run sheet at
packaging station
System indicates
what product label
should be applied
on the product
Scan product
label at the
packaging
station
System indicates
on which pack
cavity to place
the product
Pack is built and
closed
Forklift driver
loads packs
In opposite order
in which customer
will use them
44
Label Error Proofing
Technical Solution Summary Sheet
?
Auto verify bar code quality
–
–
–
?
1, 2
?
Verify part label to ship label
1. Print bar code label (shipping or part) on
printer
2. Verifier within printer verifies bar code
quality
3. Audio or visual signal returned to verify
quality
–
–
–
–
Necessary Technology
–
1 label printer with label verification device
included
–
–
–
Set-Up Card 1
Part Label
3
?
1. Scan set -up card into error-proofing intelligence
system
2. Scan part label for part or container of parts to
be packed into shipping container
–
–
3. Scan shipping container AIAG label to verify it is
correct
4. Communication to operator that labels are
correct (communication may include audio or visual
signals or printed verification)
Necessary Technology
1 base error proofing intelligence system
1 handheld scanner
Verify part label and print ship label on demand
1. Scan set-up card into error -proofing intelligence system
2. Scan part label for part or container of parts to be packed
into shipping container
3. Print shipping label corresponding to part label on demand
4. Apply shipping label to shipping container
5. May scan shipping label to verify part label to shipping label
–
–
–
?
Necessary Technology
–
–
–
1 base error proofing intelligence system
1 handheld scanner
1 printer
Set-Up Card
Part Label
Shipping Label
1
4
Shipping Label
5
3
2
2
Print/apply part and shipping labels on demand
?
–
1. Scan set -up card into error proofing intelligence
system
–
–
–
2. Part label is printed on demand
3. Part label is manually or automatically applied
4. Shipping label is printed on demand
–
5. Shipping label is manually applied to shipping
container
6. May scan part label and shipping label for
verification
–
?
?
–
–
–
1 base error proofing intelligence system
1 label application device (if label automatically applied)
1 handheld scanner
–
2 printers
–
–
–
–
–
1
–
–
–
Download customer schedule to error proof system
Part label is printed on demand
Part label is applied (can be automatic or manual)
Part label is scanned by a fixed scanner to verify sequence
Shipping label is printed on demand
Shipping label is manually applied to shipping container
Shipping label may be scanned to verify
–
–
–
–
–
Communication technology to facilitate downloading information from
mainframe
1 base error proofing intelligence system
1 label application device (if label automatically applied)
1 handheld scanner and 1 fixed scanner
2 printers
?
1. Download production schedule to error proofing system
2. Part label is printed on demand at the earliest possible poi nt
3. Part label is applied (manually or automatically) to the basic
shell of the part
4. Label is scanned by a fixed scanner to determine the part
number to be built
5. Part is assembled according to the label
6. Shipping label is printed on demand
7. Shipping label is manually applied to shipping container
8. May scan shipping label to verify it to the part label
Necessary Technology
–
–
–
–
3
1 base error proofing computer
1 label application device (if label automatically applied)
1 handheld scanner and 1 fixed scanner
2 printers
4
5
Set-Up Card
Part Label
1.
2.
3.
4.
5.
6.
7.
Verify Build Process to Part Label
Necessary Technology
Necessary Technology
?
?
Verify Part Label To Ship Label and Sequence
–
–
–
–
–
–
–
3
4
7
6
2
4
Shipping Label
2
3
7
3
1
5
6
5
44
1
2
4
8
47
45
Label Error Proofing
Advanced Technical Solutions
?
Serialized part labels to provide traceability
–
–
–
–
–
–
–
–
–
?
1.
2.
3.
4.
5.
6.
7.
8.
9.
Scan set-up card (at model change) to reset part label printer and all scanning points
Serialized part label is printed on demand at the earliest p ossible point
Part label is applied (manually or automatically) to the basic shell of the part
Label is scanned to determine the model & to enable correct parts’ assembly
Part label is scanned at key process and control locations to capture data
Scan set-up card (at model change) to reset printer & pack count
Scan part label and update pack count & database
Print shipping label (potential for including 2D symbology) on demand and update database
Apply shipping label
Necessary Technology
–
–
–
–
1 base error proofing computer + multi-user database
1 label application device (if label automatically applied)
1 handheld scanner and fixed scanners for each point of data capture
2 printers
9
8
3
5
8
4
2
1
6
7
46
Label Error Proofing
Advanced Technical Solutions
?
Integrated error proofing with PC&L to enhance traceability
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1. Scan set-up card (at model change) to reset part label printer and all scanning points
2. Serialized part label is printed on demand at the earliest possible point
3. Part label is applied (manually or automatically) to the basic shell of the part
4. Label is scanned to determine the model & to enable correct parts’ assembly
5. Part label is scanned at key process and control locations to capture data
6. Scan set-up card (at model change) to reset shipping label printer & pack count
7. Scan part label and update pack count & database
8. Print shipping label (potential for including 2D symbology) on demand and update database
9. Apply shipping label
10. Update inventory & production counts
11. Scan shipping label for shipping documentation and update inventory
Necessary Technology
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1 base error proofing computer + multi-user database + Link to the PC&L system
1 label application device (if label automatically applied)
1 handheld scanner and fixed scanners for each point of data capture
2 printers
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8
3
10
11
5
8
4
1
2
7
6
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Label Error Proofing Example:
Error Proof Smart Station (EPSS)
1. Scan Build In Process Card to setup production build in AMOS (Automated
Move Order System)
2. Define ship to location and quantity to build per schedule
3. When first standard pack is complete scan Process Move Order
4. When prompted scan part number on finished part in shipping container
5. AMOS interfaces with mainframe move order system and generates container ship
label.
6. Barcode / Scan / Verify with QCS (Quality Check System).
- Scan master barcode on build template used to set up production build
- Scan part number on finished part in shipping container
- Scan part number on shipping label generated by mainframe to ship container
- Scan serial number field on ship label to generate “O.K. Ship” label
EPSS consist of two separate systems that can stand alone or used together
1. Automated Move Order System (AMOS) which is configured to work with your
existing move order system.
2. QCS (Quality Check System) which is a second party verification system to generate
an ok to ship verification label.
Location: Delphi-S Saginaw
48
Appendix
49
Delphi Label Error Proofing
Appendix
? This
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appendix contains:
Labeling Process Gap Assessment Definition
Labeling Process Gap Assessment Evaluation Criteria
Labeling Process Gap Assessment Tracking Form
Label Best Practice Look Across Sheet Example
Additional Labeling Error Proofing Best Practice Examples
References
50
Labeling Process
Gap Assessment
? Purpose
– Define the Expectations for Label Error Proofing, in terms of:
» Leadership
» Part Labeling Instructions
» Container Labeling Instructions
» Changeovers
» Part Control
» Part Label Control
» Shipping Label Control
» Repair Loops
» Containment Areas
» Label Error Detection - Part Labels
» Label Error Detection - Ship Labels
51
Labeling Process
Gap Assessment
? What?
– Gap Assessment - The LEP Gap Assessment shows how effectively the
system has been Error Proofed to reduce that risk. The Gap Assessment
includes common root causes and counter-measures that have proven
successful against those causes.
– Dock to Dock Assessment - For each product family, or "value stream,"
conduct a system-wide assessment, using the LEP Gap Assessment form.
Do a consistent evaluation of operations and systems, with respect to Label
Error Proofing.
– Assess Critical Operations - Each operation within a product family's flow
should be reviewed. If the part changes identification at that operation (e.g.
a new component or label is added), then that operation should be
assessed. All labeling, packout, audit, containment and shipping areas
should also be assessed.
– Tracking Form - The LEP Gap Tracking form is a summary form used to
record the "score" for each critical operation in a Product Flow or Value
Stream.
52
Labeling Process
Gap Assessment
? Who?
– Gap Assessment - Members of the Plant Label Error Proofing team should
complete the Assessments.
–
Approval - Each Gap Assessment should be approved by the appropriate
managers from Manufacturing, Quality, Industrial Engineering, and
Process/Tool Engineering.
–
Tracking Form - Members of the Plant Label Error Proofing team should
maintain the Tracking Forms.
53
Labeling Process
Gap Assessment Evaluation Criteria
LABEL ERROR PROOFING GAP ASSESSMENT - Page 1 of 3
LOCATION:
PRODUCT:
DATE: __________
ASSESSORS
1. Label Error
Proofing
Leadership
2.Work
Instructions for
Part Labeling
3.Work
Instructions for
Container
Labeling
(Champions)
(Quality Engineer)
(Ind. Eng/Mfg. Eng)
1
2
LEVEL
3
Leader and staff do not
actively support Label Error
Proofing (LEP). Impact of
Label Errors on the
customer is not known.
Comments:
4
5
Improving Label Errors is in
the Business Plan,
supported by a Label
Champion & Team. Plant
has communicated (LEP) to
the workforce. Label errors
and lessons learned are
reported monthly.
Resources (money and
people) are committed to
preventing Label Errors.
When an error occurs, it is
immediately communucated
within the Division.
Corrective actions and
lessons learned are shared
across the Division.
Work Instructions exist and
are visual and accessible,
but there is no evidence that
they are followed
Work Instructions exist and
are visual & accessible.
There is some evidence,
that the procedures are
maintained and followed.
Work Instructions exist and
are visual & accessible.
There is clear evidence,
through documented audits,
that the procedures are
maintained and followed.
The Changeover Instructions The Changeover Instructions
exist and are visual and
exist and are visual and
easily accessible.
easily accessible.
Workplace Org. techniques
have been used to locate
Changeover materials in an
orderly manner at the point
of use.
The Changeover Instructions
include some mechanism
(eg a Checklist or a First
Piece Setup) that helps
make Changeovers a
Significant Event .
Changeover Instructions
include Error Prevention or
Detection to ensure that the
Changeover is done
correctly every time.
(eg Component Scanning or
2nd party verification)
No Work Instructions exist Work Instructions for
for ensuring that Labeling is Labeling exist, but are not
done correctly.
visual and easily
accessible.
No Work Instructions exist Work Instructions for
for ensuring that Labeling is Labeling exist, but are not
done correctly.
visual and easily
accessible.
There is no visual Work
Instructions for how to do a
Changeover.
4.Changeovers
Label Errors are tracked and
5 phase corrective action
reports initated. No
Divisional direction to share
lessons learned and develop
best practices.
(Manufacturing Supt.)
LEVEL
Leader and staff are
committed to Zero Label
Errors and have a process in
place to achieve it.
Evidence exists that Label
Errors have been
significantly reduced.
Corrective actions and
lessons learned are shared
across Delphi.
Work Instructions exist and Work Instructions exist and Work Instructions exist and
are visual and accessible, are visual & accessible.
are visual & accessible.
but there is no evidence that There is some evidence,
There is clear evidence,
they are followed
that the procedures are
through documented audits,
maintained and followed.
that the procedures are
maintained and followed.
54
Labeling Process
Gap Assessment Evaluation Criteria
LABEL ERROR PROOFING GAP ASSESSMENT - Page 2 of 3
LOCATION:
PRODUCT:
DATE: __________
ASSESSORS
(Champions)
(Quality Engineer)
(Ind. Eng/Mfg. Eng)
(Manufacturing Supt.)
1
2
LEVEL
3
4
There is no control over
Labels. The part labels or
5. Part Label
ship labels are Preprinted
Control
and stored in a haphazard
fashion.
There is no control over
Labels. The part labels or
6. Shipping Label
ship labels are Preprinted
Control
and stored in a haphazard
fashion.
There is no Workplace Org.
on parts and/or containers in
7. Part Control the area.
The inventory of Labels is
large, but controlled and
organized.
5
LEVEL
Label inventories are
Labels are printed
minimized. Labels not in
automatically, only on
use are well organized, with demand and applied
Non-Running Labels locked immediately.
out.
The inventory of Labels is
Label inventories are
Label inventories are
Labels are printed
large, but controlled and
minimized, but controlled
minimized. Labels not in
automatically, only on
organized.
and organized.
use are well organized, with demand and applied
Non-Running Labels locked immediately.
out.
Workplace Org. is in place Workplace Org. is in place Inventories are minimized
All extra parts and
for parts and containers, but for parts and containers, but and there is a system in
containers, including
inventories are large.
inventories are minimized. place (eg Parking Ticket) to partials, have been
control extra parts and
eliminated.
partial containers.
There is no instructions for There are instructions for
There are clear & visual
Error Detection has been
Repair Loops have been
reintroducing parts correctly. reintroducing repaired parts instructions for reintroducing implemented to detect
eliminated. (eg Error
It is left up to an individual to or for replacing defective
repaired parts or for
repaired parts that are being Proofing has been
8. Repair Loops
return parts to the proper
parts w/ correct part but
replacing defective parts w/ re-introduced incorrectly.
implemented to eliminate
container, for example.
some evidence they are not correct part and evidence
(eg ID Scan repaired parts defects or 100% of defects
always followed.
that they are followed.
for match to current part no.) are immediately scrapped.)
There are no instructions for There is a procedure for
correctly handling parts and Containment (including how
containers in Containment. to handle and replace non9. Containment
conforming parts) but some
Areas (e.g. GP-12)
evidence it is not always
followed.
Comments:
Label inventories are
minimized, but controlled
and organized.
The Containment area is
orderly and visual. There is
a clear & visual procedure
for Containment (including
how to handle and replace
non-conforming parts) and
evidence it is followed.
Error Detection has been
implemented to detect
Contained parts that are
being re-introduced
incorrectly. (eg ID Scan
repaired parts for match to
current part no.)
Containment has been
eliminated.
55
Labeling Process
Gap Assessment Evaluation Criteria
LABEL ERROR PROOFING GAP ASSESSMENT - Page 3 of 3
LOCATION:
PRODUCT:
DATE: __________
ASSESSORS
(Champions)
1
(Quality Engineer)
(Ind. Eng/Mfg. Eng)
2
LEVEL
3
None
Successive Verification
(Manual)
Multi Leveled Successive
Verification (Manual)
None
Successive Verification
(Manual)
Multi Leveled Successive
Verification (Manual)
10. Part Label
Error Detection
11. Ship Label
Error Detection
(Manufacturing Supt.)
4
5
LEVEL
Part Labels Scanned and
Verified; Repaired parts
Scanned and Verified;
Audited parts Scanned and
Verified.
Part Labels printed only on
demand and immediately
applied, early in the
process. The Labeling
Process includes Error
Proofing to ensure the
correct Part Label every
time.
Container/Ship Labels
Container/Ship Labels
Scanned and Verified, where automatically printed on
possible (eg 2nd party hand demand, based on scan of
scans container label and
part labels or weight count.
several part labels to ensure Ship Labels are immediately
a match.)
applied.
Comments:
56
Labeling Process
Gap Assessment Tracking Form
EXPLANATION FOR COMPLETING LEP GAP ASSESSMENT TRACKING FORM
Product Family - The
Assessments should be
completed with a "Dock to
Dock" focus. This means
following a part from start to
finish, focusing on steps in the
process where a Labeling
Error could occur.
ID Station - Each step in the
process should be reviewed.
(Consult a Process Flow Chart,
if necessary.) If the part
changes identification, then that
station should be Assessed.
All labeling, payroll and shipping
areas should also be included.
LABEL ERROR PROOFING
GAP ASSESSMENT TRACKING SHEET
Product Family
Value Stream
Department
Name
Plant
Date
Summary of Gap Assessment
Container
Part
Labeling
Leadershi Labeling Procedure Changeo Part Label
ID Station
p
Procedures
s
vers
Control
Container
Label
Control
Part
Control
Repair
Loops
Containme
nt Areas
Part Label
Error
Detection
Ship Label
Error
Detection
57
Labeling Best Practice
Look Across Sheet
? An
Excel Spreadsheet is used to track progress on
implementing required practices across an entire division.
Required practices are listed down the left side and
summary information for each site is listed across the top.
The summary status shown on the main worksheet (tab) for
a given site is the worst case for any line at that site and is
obtained by referencing the summary status from that site’s
specific worksheet. Conditional formatting was used to
“color” the cells to indicate compliance status. Red means
non compliance and no specific plan in place to address the
non compliance. Yellow means non compliance, but a plan
is in place with responsible persons assigned and target
dates set. Green means compliance with the best practice
or requirements. These “look across charts” are reviewed
with management to track progress towards compliance
with required labeling practices.
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Labeling Best Practice
Look Across Sheet
? In
the examples shown on the next two pages, Delphi
X has 5 sites. The first sheet shows the summary for
all sites or factories within Delphi X. The second
sheet shows label practice compliance for site A
within Delphi X.
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Labeling Best Practice
Delphi -X Look Across Sheet
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Labeling Best Practice
Delphi -X Look Across Sheet
61
Label Error Proofing Best Practice
Examples
Dual Label Verification:
? Some
customers require 2 labels per container, one on
each end. Operators manually apply the labels to each
end of the container. Occasionally, the labels do not
match.
? Dual,
fixed scanners were positioned on opposite ends of
the box. A computer interface controls the scanners and
ensures that both labels are scanned virtually
simultaneously. The part number, serial number and
quantity fields must match on each label before the
container can be processed any further.
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Label Error Proofing Best Practice
Examples
Special Label Over-label:
? One
customer's requirements included having information
that was only available at the time of order included on the
shipping label (tally number). Products had to be built and
packed ahead of time because the customer also required
immediate shipment of orders. A generic Delphi label was
used containing the Delphi part number. Also, the
customer's part number had to appear on the container
label and, the customer's part number was nothing like ours
(19 character alpha-numeric vs. 8 digit numeric).
63
Label Error Proofing Best Practice
Examples
Special Label Over-label:
? When an order was received, the operator requested new
container labels with the appropriate information (customer
part number and tally number). The operator used a cross
reference sheet to match the appropriate customer part
number and Delphi part number before performing the overlabeling operation. The old (Delphi part number label) serial
number was scanned and transmitted to the shipping system.
The new (Customer part number) serial number was then
scanned and also transmitted to the shipping system so the
shipping system could keep track of the box and its contents
by serial number. No association between old and new label
part number was maintained. (The shipping system was a
main frame computer application. Changes were difficult and
expensive to make.) Occasionally, the wrong box was overlabeled, because the operator only had to scan the old and
new serial numbers to inform the shipping system of the label
change.
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Label Error Proofing Best Practice
Examples
Special Label Over-label:
?A
hand-held, programmable scanner was introduced into
the process. The scanner was programmed to cross
reference the customer part number to the Delphi part
number. The process was changed to have the operator
scan both part number and serial number on both labels. If
the part numbers cross reference correctly, the scanner
would transmit the serial numbers as before. This allowed
additional error proofing without making expensive
changes to a large, unfriendly computer system.
65
Label Error Proofing Best Practice
Examples
Part Locked in Fixture:
? An operator placed an electronic module in a fixture for final
test. If the unit passed, a serialized label was printed and the
operator placed the label on the module. Because the test
time was long enough, the operator was able to operate more
than one fixture. Occasionally, the wrong label would be
placed on a module.
? By
adding a solenoid controlled locking device to the fixtures,
the tester was able to control when the part could be released
from the fixtures. Fixed bar code scanners were added to
each station and the process was changed so that the
operator had to place the label on the module after successful
test and the tester has to see the proper label on the proper
module in the proper location before the module is released
from the fixture.
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Label Error Proofing Best Practice
Examples
Add Bar Code to Customer Required Labels:
? Some
time in the past, we had agreed to supply radios with
additional colored stickers on the front to aid the assembly
plant operators in selecting the proper radios to place in
vehicles. Sometimes Delphi operators would forget to apply
these labels or the wrong color labels would get applied. Even
though the proper bar coded end item label was on the part, if
the colored label was wrong, a label error had occurred.
? By
having the label manufacturer bar code a color code on the
color label (a white strip was left on the new labels to
accommodate the bar code), the secondary colored labels can
be scanned at pack out to ensure the proper labels are
attached to the product.
67
Label Error Proofing Best Practice
Examples
Bar Code Verifier:
? Occasionally
the thermal transfer printers used to print bar
code labels would experience problems and label with poor
bar code quality would be produced. The label produced
would be of poor quality, but the scanners used by Delphi
in many cases could read these labels, so the poor labels
were not discovered in the normal manufacturing process.
? Bar
code verifiers were utilized on an audit basis (twice a
shift) to actually measure bar code quality. When labels of
poor quality are detected, appropriate actions can be taken
to quarantine the bad labels and take corrective actions
68
References
? Delphi Common Procedure Requirement
– Product and Shipping Container Labeling
#7
? Delphi
Automotive Systems Labeling Workshop
? Delphi-D Intranet Label MTT Home Page :
http://mtt.delcoelect.com/Labels/
? Delphi-A Intranet Label Task Team Home Page:
http://apollo.delphiauto.net/customersatisfaction/ltt/ltt.htm
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