Saving Time With Bar Code Data Entry

Client: Manufacturer of Capacitors and Electronic Components

Project

For more than 40 years, a manufacturer of capacitors, RC networks, and transformers has been providing quality products and services to their customers. Many of their products are used in building machines too important to fail, such as airplanes and submarines. It was imperative that each stage of the process be recorded in accordance with government requirements and ISO 9001:2000 and AS9100B standards. Our client had been keeping track of process time with “pen and paper.”  This had become inefficient and our client needed a better method for keeping track of the time spent during each step of the manufacturing process.

Solution

We designed and wrote a custom time tracking system to record assemblers’ time on each step. One requirement of the system was that it could not slow down production.  As the assembler began a step, he or she scanned their ID badge and the respective barcode on the work order. After a step’s completion, the assembler scanned a “step complete” barcode which stopped the time on that step. If the worker took a break or left for the day, they scanned a “step paused” barcode which paused the clock until someone returned to complete it. Our system permanently recorded information required by government agencies and insured that no steps were omitted.

Results

In addition to the manufacturing times becoming more predictable and product quality improving, our client was able to use the collected time-tracking data to find deficiencies and bottlenecks in the manufacturing process. Problems were addressed and the manufacturing process became more efficient. The time-tracking system produced information on how long specific assembly projects take. This helped our client give their customers more accurate completion time estimates on new orders. Product quality improved and project scheduling became more accurate thus improving customer satisfaction.