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Lessons learned: On the packaging line

Here are actual lessons learned about what actually happens in the plant and on the line, from those who have conducted live supply chain pilot tests.

Printing and reading codes
1. Move 2D barcodes away from other barcodes on the label. Multiple barcodes, such as a UPC/EAN and a DataMatrix, on a label should be separated so that scanning is more efficient and accurate. This is especially important for hand scanning—in some situations operators had to cover a traditional linear barcode with their finger so that it would not be read.

2. Use a fixed barcode scanner on the conveyor that can read across the conveyor.

3. Watch for vibration. It can affect both printing and scanning.

4. Make sure label roll changes on label printers don’t cause serial numbers to get out of sync.  In one pilot, when the printer ran out of labels, the system buffered the current label and paused to wait for labels to be reloaded. However, upon reload, the system printed the label again, causing all aggregations to be off by one. Make sure your QA process is modified to check not only whether the label printed properly, but also whether it was the correct number in the serial sequence. 

5. Manual scanning slows down the process. Picking up each bottle, scanning the barcode, and putting the bottle in the case takes more time and precision than just packing the bottles in the case and taping it up.

6. Test printing on multiple carton substrates. During typical production runs, you may use multiple lots of cartons from different suppliers, each of which might have subtle but meaningful variations in printing due to substrates from different batches or board suppliers. Ensure that all conceivable variations are tested.

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