Traceability System can be defined as “the ability of the system to trace the history, application or location of an entity by means of recorded identifications.”
For discrete manufacturers, the traceability system can track and trace each component that comprises your product – from suppliers and manufacturers through assembly and final delivery to customers.
Basics of Traceability
Use of technologies such as direct part marking for discrete manufacturers, where parts and components receive a permanent mark either as they enter assembly or by suppliers.
1D and 2D bar codes
Engraved marking system
Need of Traceability System
To help close some of the information gaps that exist in disparate supply chains, track warranty data and meet customer safety and demand requirements.
Protect Your Reputation
Recalls are Costly…
Components of a Solution
Track and trace of critical components within the manufacturing process begins with both process and technological changes.
In order for traceability system to be effective, companies must shift from error-prone manual processes to automated ones – capturing, storing and managing information automatically.
Identification of defects and prevention of outflow.
Data accumulation and applications.
In case of a problem with a machine in the field, once the product serial number is identified, the traceability system allows us to trace any quality-related information recorded at the manufacturing site.
The tracked information of our machines in the field is analyzed and used to prevent potential problems from occurring in the machines, and also to manufacture products with better quality at manufacturing sites.
Compatibility with various control system environments such as Siemens, Allen Bradley, Mitsubishi Etc.
In case of a machine malfunction in the field, once we identify the product's serial number, our traceability system allows us to trace, for example, the serial numbers of the installed parts, the factory inspection results, and any adjustments made prior to shipment. As a result, we can rapidly diagnose the cause of the malfunction and also list the machines that may experience problems, so that we can take some preventive measures.
Extremely fast, sub-second response times. Simultaneously provide real-time responses to hundreds of connected stations.
Graphical Track and Trace
With model path configuration, all build prerequisites are checked at each station.
Part Status Storage
Store process data for every part at any station.
Numerous web-based reporting capabilities for queries and reporting on part status, station, date/time, containment, diagnostics/events, production history and more.
Make sure regulatory processes and compliance standards are met.
Server Monitors and Diagnostics
Get system limit warnings, alarms, and diagnostics such as average response time issues, improperly formatted serial numbers, controllers not connected or responding, and much more.
Increase quality and decrease manufacturing costs. Effectively manage containment campaigns for warranty claims.
Simple & Easy Turnkey Solution
Save in-house resources and get immediate ROI with a turnkey traceability solution. Simply add modules on the same application, such as Vision Image Management or JEM Work Instructions as you need them.
Data Acquisition Options
Several type data acquisition available as per requirement.
Compatible with several types of protocols such as Modbus, provirus, device net.
Expert engineers for system installation and customize programming.
“Real-time transparency limits the scope and impact of any potential recalls”
Real-time Traceability systems (RTTS) When combined with a robust data management system, bar code scanning solutions can create a versatile RTTS.
Implementing a wireless local area network (LAN) within a production or staging facility enables a business to collect and correlate the various data in real time as it moves to, from and throughout a facility. Respond instantly with mobile computers equipped with voice, and/or bar code scanning.
Traceability technologies and processes ensure product quality standards are met and give real-time information about production and equipment.
Track production information back to the exact date, time, supplier components, operator and machines used.
“Real-time information puts customer satisfaction & safety first”
Increase customer satisfaction and safety
In the event a recall does take place, manufacturers are able to minimize the impact by only recalling those items with the specific serial numbers that were built with the faulty component, material or process – thus significantly reducing expenses and customer impact.
Meet government and compliance mandates
Ease the burden and lessen the chances for fines and penalties associated with noncompliance. Meet the challenges of stricter government regulations and manage detailed product histories to meet discrete and process manufacturing standards and regulations.
Improve data accuracy
Reduce human error. Components or ingredients are handled within the manufacturing plant with the use of bar code scanners and wireless data technology. Some also use RFID, mobile/industrial computers, data engraving, etc.
Automatically capture product, part, employee number, quantity and supplier information, etc customized as required.
Increase operational productivity
Save millions in lost revenue, recall costs, damage control campaigns, litigation and fines. From an operations perspective, automated KanBan for just-in-time (JIT) line side replenishment of component parts can also significantly increase productivity.
Protect your brand and bottom line
Mobile track-and-trace solutions can prevent quality issues before they occur or, in the event of a product recall, allow manufacturers to act swiftly as well as narrow the scope of the recall to reduce exposure to negative brand impressions and damage to revenues.
Reduce warranty claim costs
Traceability enables manufacturers to accurately analyze the root cause of a product or part failure to recover warranty costs from liable suppliers.
Focus on generating revenue
With automation and traceability solutions for discrete manufacturers you can track warranty and part information to up-sell and cross sell complementary products and services.
In addition, labor hours can be reallocated to focus on revenue-generating activities versus the double reporting that occurs when data is collected manually and then later transferred into a computer system.