We recently had three bins mislabelled (right as left).This happend after a periode of 13 months after starting the program or after shipping approx 1000 bins

We are looking for systemic errors in the process to eliminate the same

We presently have

1.Visual Aid :Showing the location of part number and differnece between Left and Right part numbers
2.Quality Alert( issued after the incident)
3.The bin locations are fixed,marked with Coluor code and Part number on both Operator side and Fork lift side
4.The bin labels are clour coded and have picture on the label
5.Two different locations for Right and Left labels
6.Operator checks all mistake proofing and first layer of audits in the begining of shift
7.Opertors are trained and they understand what they are doing
8.I do not believe operators are lazy(they are also not overloaded)
9.Noise,Temp,Lighting etc are comfortable

We are not able to increase the distance between bins due to space constraints
The interlocking between Fixture clamps and part loading in the bin is adding cycle time

The upper management is not intersted in RFID or Part labelling

I understand the mis-labelling the second most supplier issue with OEMs

Please advise how to improve the above situation,share your experiences in simmilar situation

Regards

D.Prabhu

Did you have a look at Eliminating Mislabeled Product (http://elsmar.com/Forums/showthread.php?t=16920)?

Can there be a black or colored band on the edge of the label? On the right edge of the right label, and the left edge of the left label?

We recently had three bins mislabelled (right as left).This happend after a periode of 13 months after starting the program or after shipping approx 1000 bins

We are looking for systemic errors in the process to eliminate the same

We presently have

1.Visual Aid :Showing the location of part number and differnece between Left and Right part numbers
2.Quality Alert( issued after the incident)
3.The bin locations are fixed,marked with Coluor code and Part number on both Operator side and Fork lift side
4.The bin labels are clour coded and have picture on the label
5.Two different locations for Right and Left labels
6.Operator checks all mistake proofing and first layer of audits in the begining of shift
7.Opertors are trained and they understand what they are doing
8.I do not believe operators are lazy(they are also not overloaded)
9.Noise,Temp,Lighting etc are comfortable

We are not able to increase the distance between bins due to space constraints
The interlocking between Fixture clamps and part loading in the bin is adding cycle time

The upper management is not intersted in RFID or Part labelling

I understand the mis-labelling the second most supplier issue with OEMs

Please advise how to improve the above situation,share your experiences in simmilar situation

Regards

D.Prabhu

Hello Prabhu,

1.You may paint a 'distinct coloured triangle' on left hand and right hand bottom of the respective bins.

2.If the bins are stacked one over the other,with locating pegs at the bottom then a simple design change for LHS & RHS bin's pegs will do the trick.A simple poke-a-yoke.

Hope this helps

/Umang :bigwave:

Have you tried using symbols on the barcode labels?

For example left is diamond, right is square for Product A,
For exampe for product B: left is fish, right is cat and so on.

We have been successful with Honda with this method.

We recently had three bins mislabelled (right as left).This happened after a period of 13 months after starting the program or after shipping approx 1000 bins
We are looking for systemic errors in the process to eliminate the same
We presently have
<snip - multiple poka-yokes, etc.>

We had a program (now obsolete) with similar issues. Even after all the automated detection and footprinting improvements were made, we still had a few instances of reversed labels.

These were determined to be off-line errors - after sorting or rework or simply a finished bin pulled out of the way without a label, despite instructions for extra care or prohibiting the practise.

I think our last modification was actually putting a colour code on the parts during assembly that matched the colour on the label applied after bin fill, to be verified in final audit.

B.G. Wiehle

are they batching?

you have a lot of error proofing 'doohickies' in place now.

typically people make errors because they can. you need to seriously look at eliminating any ability to put the wrong label in the wrong place. oen piece flow techniques often help.

what is the current process?

Have you addressed these potential failure modes?

1) how are parts handled that have been repaired in a different area?

2) when the line switches over, how is the partially filled box handled?

3) when the line switches over, how is the switch identified?

4) are all old labels removed from the containers?

5) is the review area cleared when the line changes over?

6) are all operator on the line or in the cell aware when the line changes over?

7) is the label printer switched over at the right time?

8) are labels printed before they are needed?

9) are there "loose" labels on the floor, in work areas, supervisors desk?

Walk your process on the off-shifts to verify that process is followed on all shifts.

Your solution is here... epecllc.com

Your solution is here... epecllc.com

What is your experience with this organization?
Are you associated with them?

Stijloor.

I am...my son owns the company and developed the software. I worked for Lear Corp for 23 years and had the same issues as you discribed so the controller was born and have placed over 25 units in production and must say they work! I am now working for EPEC and developing new products lines that fall in the error proofing catagory.

I went to the website (epecllc.com), but could not find anything that would help prevent the mislabeling that occurred.....

mthouin, can you explain how it would prevent the labeling error under discussion?

Can you please explain as to how EPEC monitor works,and how do you propose to tackle the OP's problem.

/Umang

Your solution is here... epecllc.com

Hello mthouin,

Please explain to us how this labeling error-proofing works.

We're here to help others and to learn.

Thank you in advance for your contributions.

Stijloor.

Part is placed in a nest for a 1 to 2 sec evaluation of color and hand. If the color matches the selected part number the ultrasonic sensors are activated
over the pack out containers (1 over LH/ 1 over RH) if the part is a LH then the part is allowed to be packed out in the LH container. Upon seeing the motion the count goes up one (C = C + 1). If the LH part is packed in the RH container an alarm is sounded and the equipment is diabled until a supervisor resets it (accountability). Once the container is full a label is printed for that container and the ultrasonic sensors again are activated to insure the label is placed on the correct container.

We have had one of many recent problems with incorrect labeling and it got to the customer, which resulted in a NC. Currently, we are trying to figure an efficient way to reduce errors on labeling and special requirements. Right now, our method is having a checks and balance. The warehouse assistant reviews, then the warehouse manager verifies however this process is still not efficient. Does anyone have any recommendations on what we can do to reduce errors in our system? Any help would be greatly appreciate.Thank you!:bigwave:

We have had one of many recent problems with incorrect labeling and it got to the customer, which resulted in a NC. Currently, we are trying to figure an efficient way to reduce errors on labeling and special requirements. Right now, our method is having a checks and balance. The warehouse assistant reviews, then the warehouse manager verifies however this process is still not efficient. Does anyone have any recommendations on what we can do to reduce errors in our system? Any help would be greatly appreciate.Thank you!:bigwave:

Are these label information or label location errors?

Stijloor.

We are trying to figure out a way so that we do not forget to send special labels. We create the special labels are requested by the customer. Since we are forgetting to send them, we are lacking some important piece in our verification system.

I received your email and I do have a way that will probably help you. It's been proven many times over and works in conjunction with SAP and QAD if that helps. I'm not sure of all the rules here but would be happy to send you what info I have and can tell you how the system should work. Send me a private message if your interested and I'll contact you to explain further.

I received your email and I do have a way that will probably help you. It's been proven many times over and works in conjunction with SAP and QAD if that helps. I'm not sure of all the rules here but would be happy to send you what info I have and can tell you how the system should work. Send me a private message if your interested and I'll contact you to explain further.

Why not share what you have for all our Cove Members to enjoy?

Cove Rules? Read the TOS.

We are a sharing group. :agree1:

Stijloor.

To be honest I would need more info on the application to insure your going to get positive results. I did explain some of it in the past (see post) but am willing to help out anyway I can for particular situation. It can be involved especially when it come to packing out different "hands...LH/RH" or different colors. If anyone has particulars then send me an email and I'll be happy to share what I know

Hi

Thanks for all the feedback
The system is quite stable now
We implemented colour code for left and right and added vertical bar on the barcode labels

Regards

Prabhu.D:thanx: