Case StudiesWireless barcode reading solution boosts inventory control
Specialist glass unit manufacturer Clayton Glass boosts customer service levels through barcode track and trace solution from Barcoding.co.uk. 
Building a reputation for specialist insulated glass units in today's economy is not easy. It takes dedication to lead the market in product development and ensuring your customer service levels are second to none, which keeps your customers coming back for more. Clayton Glass in Stanley, County Durham, north east England, is a company that fully understands the need to lead the market through innovation and service, demonstrating that it is committed to its customers and providing products of the highest possible quality.
Underpinning continuous improvement
The dominant theme of business at Clayton Glass is continuous improvement in 'on-time in-full orders', superior product quality and exemplary customer service. Richard Teasdale, Financial Controller and Systems Administrator, is in charge of ICT. He points to the investments the company has made so far and indicates the way ahead as the company implements technology to enable it to achieve optimum performance in all areas of its operations. These include investments in people, manufacturing, logistics and now auto ID for accurate track and trace.
“Our warehouse contains vast numbers of products and we needed a simple way to ensure that when orders were put through to it we were able to pick the exact number of items,” says Richard Teasdale.
“We have over 120 major customers. All of our clients demand that we remain true to our word of providing 'on-time in-full orders' and we do our uppermost to achieve these levels, hence, we are constantly investing in the company. We are eradicating mountains of paper records and missing units by putting increasing emphasis on barcodes. Our target is to be able to apply barcode reading throughout the business to underpin accuracy improvements across the board,” he continues.
Moreover, barcode-based traceability of products within the warehouse is just stage one out of the 10 step plan he has for taking forward the company's IT infrastructure.
Integrating barcode
Clayton Glass is not an entire newcomer to barcode labelling as this technique has been used for many years to label its products with EAN 128 barcodes. Richard Teasdale had long identified that the company could utilise the barcodes as data carriers for an auto ID system. He investigated various options, eventually seeking assistance from Barcoding.co.uk.
“The barcode reading solution had to integrate with our specialist Lisec production software, which runs on an Oracle database. The solution would have to be cost-effective and we were looking for a tangible return on investment. The team from Barcoding.co.uk took this on board and was able to develop and implement a system that works seamlessly. It is a slick solution and our warehouse staff find it very easy to use,” says Richard Teasdale.
Barcoding.co.uk initially recommended Bluetooth scanners, but changing circumstances required the units to be upgraded to RF Datalogic Kyman scanners running over a wireless network utilising Proxim access points.
Gaining company wide benefits
“Using barcodes helps us in many ways. First, we reduce the amount of reliance we have on paper records, second we achieve faster and 100% accurate track and trace of products within our warehouse, and third by deciding to use a wireless system we are able to make the most of the mobility that the technology brings to the warehouse. No area of the warehouse need be excluded from scanning and so we are able to locate products regardless of where they are stored,” he says. 
Productivity and efficiency have risen to new levels with the speed and accuracy the barcode system brings to the business. The warehouse staff are able to work quicker as all they need to do is scan the items straight into the system. This is significant as Richard Teasdale says that the company can expect to follow through with expansion plans based on existing staff.
“We are already saving in the region of £25,000 with the implementation of the wireless barcode system. We have gained speed, accuracy and real-time information, with a further benefit of comprehensive reporting,” says Richard Teasdale.
“By using barcode technology for inventory management we have opened the door to further applications for auto ID. For example, we are developing our quality control procedure. We will be able to transfer handwritten records of failed units directly into our management system simply by scanning the label. We will also be able to generate delivery notes based on the actual delivery. This tightens up traceability outside our factory gate and reduces lost unit claims and will help us to challenge such claims,” he concludes.
Barcoding.co.uk enables Primeur to operate in real time
Radio frequency data collection and communications links seamlessly with leading soft furnishings supplier's ERP system, delivers real-time benefits and supports excellent customer service. 
Primeur is the UK's leading manufacturer, importer and distributor of soft furnishings. Serving major and independent retailers, the company supplies such well-known names as Argos, B&Q and Wilkinson with cushions, rugs and floor mats.
The UK market for furnishings and furniture is worth in excess of £8 billion. This encourages stiff competition among suppliers. From its Bingley base Primeur operates a slick operation, enabling it to respond quickly to customer requirements and so retain a significant lead on its competitors.
At Bingley rapid and agile response is supported by a high-tech wireless system supplied and installed by Barcoding.co.uk, which helps the company to handle a product line of over 1126, with about 5 million individual items per year being imported.
Product throughout is subject to seasonality and so Primeur has to be flexible. The company, therefore, applies lean principles to ensure efficiency and yet Primeur must be able to handle demands effectively to maintain excellent levels of customer service. This is made possible by using the wireless real-time solution that integrates with a Strategix ERP system, which handles all the sales and purchase orders, customer and product data, etc. All operations link to this system, with barcode technology playing a lead role in enabling Primeur's personnel to perform paperless warehousing tasks.
In brief, the standard process begins with Primeur raising purchase orders with its manufacturers in India and Europe. The products are then shipped to Bingley where they are put into stock bins within the warehouses. Accuracy is paramount with barcode labels being applied not only to individual items and to batches of the same items, but also to the stock bins.
The accuracy and efficiency of the stock movement operation is where the Barcoding wireless system comes into play. The entire Primeur site - across the three warehouses - is equipped with 20 Proxim WiFi access points, comprising an appropriate mix of AP700 and AP500 devices. These enable real-time data collection and communication using handheld computers equipped with barcode scanners. The devices run terminal emulation and talk directly to the ERP system. This enables operators to place the correct item in the correct stock bin. Then by also using the portable terminals to assist with picking, accuracy is maintained with items matching the picklists displayed on the handheld devices.
Glynn Robinson is Systems Support Manager for Primeur. He talks enthusiastically about the system saying that is of “great benefit” to the company. “We are able to run a very well-managed business using real-time data. This is the right approach for us and has eliminated vast amounts of paper, which reduces operational and environmental costs and significantly boosts accuracy,” he says.
Primeur relies on Barcoding.co.uk for ongoing service and maintenance and enjoys an excellent business relationship.
“Barcoding's service is excellent, the team responds quickly to our needs and this means we in turn are able to provide the high levels of service our customers expect from us,” concludes Glynn Robinson.
Facts at a scan: Primeur wireless solution supplied by Barcoding.co.uk
20 x Proxim WiFi access points - appropriate mix of AP700, AP600 and AP500
1 x Citizen CLP desktop thermal transfer printer
2 x Zebra Technologies RW220 portable direct thermal barcode printers
4 x Datalogic Kyman.net handheld terminals
10 x Datalogic Viper handheld terminals
4 x Hand Held Products Dolphin handheld terminals
Printer consumables
Barcoding.co.uk provides the answer to Calsonic Kansei's auto ID needs
Ongoing supply of barcode technology and printer media ensures smooth running of leading automotive parts manufacturer’s assembly lines.
Calsonic Kansei is one of the world’s largest manufacturers of automotive parts. The organisation has sites worldwide to serve the need of its customers, which include well-known brands: Audi, BMW, Ford, Honda, Mitsubishi, Nedcar, Nissan, Renault, Saab, Scania and VW.
 No margin for error: Auto ID plays is essential to supporting a highly sequenced operation on CKWA's production line for Nissan.Calsonic Kansei Washington (CKWA) in Washington, north east England provides fully assembled Cockpit Modules for Nissan passenger vehicles, matching individual items exactly to each car’s build details. According to Kevin McKimm, Production Engineer, CKWA, this has to be a highly efficient process, requiring speed and 100% accuracy – there are no margins for error as the right parts must be on the right car within production lead times of less than 1 hour. Here auto ID plays an important part in supporting the highly sequenced operation, allowing the fast and accurate matching of parts to individual build sheets. This is where auto ID specialist Barcoding.co.uk provided expertise, technology and service to ensure a smooth operation throughout.
The assembly process at CKWA is interesting, being a mixture of automation and manual operation, which is governed by the in-house written and developed manufacturing system.
In all there are 40 assembly lines and stations, and several standalone assembly benches. The process begins with an AGV (automated guided vehicle) pulling into a station. The AGVs are equipped with RFID tags that transmit information to the ‘build screen’ located at each station, this is backed up with a ‘build sheet’ containing a 2D code, which accompanies the AGV around the assembly line. This information directs what needs to be loaded onto the AGV by the assembly station operators. To ensure parts are picked accurately, each item is barcoded and the label is scanned using a handheld barcode reader – CKWA use a variety of handheld devices from different vendors (Symbol Technologies, Datalogic and Hand Held Products), all supplied by Barcoding.co.uk. Depending on the job, the operators use tethered or wireless (Bluetooth) barcode readers and to read the 2D code either a Datalogic or Hand Held Products device is used.
“Auto ID underpins the smooth running of our process. By using barcodes we are able to avoid errors on many visually similar parts as each individual item shown on the build screen can be readily identified. The build sheet and 2D barcode gives a tangible interface between the IT system and the production line which make the complex sequencing operations more understandable from a production operator perspective – this allows manual recovery should a sequencing error occur within the automated system. It also allows a logical switchover point from automatic system to backup mode operation,” said Andy Smith, Programmer, CPM Engineering Manager, CKEU.
 CKWA runs a fast-moving, snag free process supported by auto ID technology.Barcoding.co.uk also supplied CKWA with Zebra Technologies thermal transfer barcode printers for printing barcoded labels, which are attached to each specific item ensuring secure and accurate identification during the assembly process. This is best explained by using a typical example such as an ignition key module where one barcode label is attached to the module and another stuck onto the plastic bag containing the key. This ensures that the key and the module match at the end of the assembly line. To ensure the printers run trouble-free and on-demand, Barcoding.co.uk supplies regular stocks of printer media to CKWA.
Kevin McKimm offers high praise of Barcoding.co.uk. “The team at Barcoding.co.uk are friendly people with whom we are on first name terms. They are extremely responsive and they understand what we do and the complex nature of our business.”
“Our process is fast moving and we cannot afford hold-ups of any sort; any assembly line stoppage is counted in tens of thousands of pounds per minute. Barcoding.co.uk are fully aware of this and are prepared to go the extra mile; for example, we even had the company’s MD deliver label stock to us in person to prevent a potential line stop.”
Barcoding.co.uk frees Avery Dennison of its tethered communications system
Extended RF system delivers WiFi benefits to world leading pressure sensitive and self-adhesive label products manufacturer. 
Avery Dennison is a global leader in pressure-sensitive technology and innovative self-adhesive solutions for consumer products and label materials. The company has been at the forefront of its market since 1935 and in 2006 reported sales of $5.6 billion. The company has global reach, with manufacturing and distribution operations in 49 countries and selling to over 89 countries.
The company’s leading market position illustrates clearly that it is an innovator in its own right. It is no stranger to new technology and at its Cramlington, Northumberland, UK, site it has gone completely wireless, based on its experience of deploying wireless networks at other UK sites.
Colin Moir, Systems Support Manager, Avery Dennison Materials U.K. Ltd, speaks enthusiastically about the benefit of wireless networking the site. "We had already installed a wireless system in the finishing department and had been benefiting from this for some time. We decided that it was time to implement wireless in the goods in area and then throughout the site. This was a phased plan that spiralled through the operation."
Avery Dennison contacted Barcoding.co.uk for assistance as it was aware of the organisation’s expertise in wireless networking. Barcoding.co.uk performed a wireless survey to ascertain how the technology would perform relative to the site topography. (Interestingly, the company has performed similar surveys at Avery Dennison sites in Milton Keynes and Dublin distribution centres and at its European Headquarters in Leiden, the Netherlands.)
The basis of implementing any wireless system depends on delivering benefits, these can simply be the need for a convenient network architecture or as in Cramlington a major productivity boost. The key business driver says Colin Moir was to speed up shopfloor jobs. He explained that even simple things such as reducing the need for shopfloor staff to walk to and from fixed-position terminals or to carry paper-based systems around, significantly makes for a quicker, more responsive and more accurate environment.
The system comprises a WiFi network designed and installed by Barcoding.co.uk that utilises Dolphin handheld computers as data collection and communication devices, also supplied by Barcoding.co.uk.
“The staff get on well with the equipment; this system has enabled them to do two jobs in one,” says Colin Moir. “The truck drivers in finishing think that the Hand Held Products Dolphins are wonderful compared with the previous equipment. Moreover, the people involved in stocktaking have quickly taken to the inventory system designed by Barcoding.co.uk, which runs on the handheld computers.”
As for an overall view on the installation, Colin Moir says: “Barcoding.co.uk has made it easy for us. Support is excellent and I can be confident that I will get a responsive service if ever I need to pick up the phone to them.” |
