ems

Raising the barcode: Why large component volumes need control processes like barcoding

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Raising the barcode: With large component volumes, control processes such as barcoding are vital

With OEMs under increasing pressure to produce and distribute products to ever decreasing timeframes but higher standards than ever, getting the manufacturing practices as smooth as possible is a major priority. Handing the management of this process and of the parts and materials needed to manufacturing partners is cost effective and logical, but also requires manufacturers to put a great deal of trust in their EMS partners. Implementing flawless control processes is one way that EMS partners can reassure manufacturers that their products are in safe hands.

Many components, especially those used in surface mount technologies, are identical with no markings or visible differentiators. EMS firms service multiple customers and support a vast array of products and technologies, meaning there are thousands of parts in circulation. At Chemigraphic, we have over 40,000 parts in play at any one time.

However, it’s vital to treat every different part as an individual, as they each have a very distinct function and purpose. Putting the wrong part in the wrong location, even though it fits physically, can be catastrophic for the product, causing immediate failure or remaining hidden as a latent fault only to be revealed years later.

In order to avoid such issues and keep on top of the exact identity and location of every component, it’s crucial for EMS providers to implement strict control processes and procedures throughout the manufacturing process.

At Chemigraphic, we are meticulous about component control. Here are just some of the control processes we use to maintain the highest standards of quality for our customers:

  1. Sourcing

We have robust systems around process governance, meaning we only source components from reputable and approved suppliers. Any issues or non-conformities arising are managed with trackable documentation which is recorded and reviewed. We are committed to carrying out regular and thorough checks and balances to manage supplier quality and drive continuous improvement.

  1. Automated barcoding

We operate an automated barcode generation system which barcodes everything in our factory: materials, equipment, personnel and products. Our Enterprise Resource Planning (ERP) system will only allow the movement of components and materials between each stage of the manufacturing process once the necessary criteria are fulfilled, allowing for full traceability. We actively manage this data which is displayed on dashboards all around the factory and our offices, enabling immediate identification and rectification of issues before they escalate.

  1. Bespoke labelling

At PCB level, our ERP generates a unique serial number per product which is automatically printed and placed by machine. This avoids any possibility of duplication, lack of serialisation, or inconsistency in placement or orientation. This is especially important when customer assembly or service personnel require access to the products through access hatches or similar.

Our surface mount stock is managed by a fully automated kitting and storage system which eradicates the risk and cost of operators picking parts from shelves.

Automated processes extend beyond the factory floor

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Automated Processes

Automation: Automated processes extend beyond the factory floor

Stewart Gadd, Technical Director, Chemigraphic

Industry and business is becoming more and more digitised across the board, from the way we sign in to a building to how we create reports on the activity we conduct. Offices are moving towards paperless operations, and factory systems are adopting more automated processes which boost productivity and cut time to market significantly. As a result, automation has become something of a buzzword across industry, with various techniques and systems emerging to streamline or speed up production.

In EMS, automation is instrumental not only in improving and speeding up the manufacturing process but also in reducing the risk of human error and ensuring consistency. That said, automated systems will not work effectively or efficiently unless they have been set up properly and this is where human skill and experience comes into play. The most successful EMS operations are those which combine the mass delivery and rigidity of automation with the intelligence and flexibility of those programming the machines.  Human operation is also required to make sure any investments are fully justified and maximised. Anyone with spare capital can buy the latest system or machine,  but using it effectively is often another matter entirely. Far too often, a new acquisition or application will sit underutilised or even dormant in a business due to ineffective or partial implementation a year later.

In terms of how we manufacture and assemble products, automated processes play a huge role in the innovative approach we take for our customers. From applying conformal coatings to protect circuitry and components in hazardous environments, to exclusive JUKI-automated kitting processes in our surface mount lines, we use smart, data driven techniques to not only increase the speed of production but also to eliminate errors and inconsistencies.

Automation_Chemigraphic

At Chemigraphic, however, the capabilities and benefits of automation reach far beyond machinery and manufacturing. Our business relies on the strength and insight provided by the data network that runs throughout the company. Collecting, analysing and acting on data, whether it relates to customer purchases, productivity levels of staff or the efficiency of internal systems, is vital in measuring and improving our overall performance. By tracking spikes, dips and other trends in the data we collect across the business, we can start to make observations on what is working well, what needs to change and successes we need to celebrate and champion.

In many ways, data collection is not a new thing. As business people and simply as people, we have always collected, recorded and analysed information and used this analysis to inform the way we develop and perform. In decades past, this data was collected manually and recorded by hand, or by mouth. Now, with computers, digital systems, the internet and the cloud, the nature of this data collection and how it’s stored has changed, as has the speed and depth with which it can be captured. Yet the principals are still the same. Watch what you do, note it down, look at what it means, and use the knowledge to do things better and more effectively.

Automation is key to our business and many other businesses without a doubt, but we need to stop thinking about it as simply a word to describe highly technical machinery. Automation is about using the tools and information we have around us to implement the best and most consistent methods of delivering the best results for us and our customers.