The Marcus Department of Industrial and Manufacturing Engineering

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Automatic Identification and Data Capture Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Outline why use automatic identification? n technologies n – – n bar code cards radio frequency tags other applications Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Why Auto. ID? identify items n eliminate errors in data collection n speed up data collection n track items n store information about items n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Auto. ID Technologies n bar codes – – n cards – – – n n n 1 D (linear) 2 D (stacked or matrix) magnetic stripe smart optical radio frequency tags contact memory voice Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State 1 D (Linear) Bar Codes most widely used technology n bars and spaces n may be numeric or alphanumeric n low storage capacity (15 -50 characters) n usually used as “license plate” n most used codes: UPC, I-2/5, Code 39, Code 128 n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State UPC Code n n n retail applications numeric, 12 digits format – a character has n n n – 2 bars and 2 spaces 7 modules (bar, space is 1, 2, 3 or 4 modules wide) dark module = 1, light module = 0 left and right are different Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Interleaved 2 of 5 Code industrial applications (distribution) n numeric, any even number of digits n format n – – start and stop characters are different a character has n 5 bars or 5 spaces n 2 are wide, 3 are narrow n odd digits are bars, even are spaces Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Code 39 (3 of 9) n n n industrial applications numeric and upper case alpha, any length format – – – start and stop characters are the same has intercharacter gap a character has n n 5 bars and 4 spaces 2 bars and 1 space are wide Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Code 128 n n n industrial applications full ASCII character set, any length format – – – different start and stop characters uses a check character for error detection a character has n n 3 bars and 3 spaces 11 modules total (bar, space is 1, 2, 3, or 4 modules wide) Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State 2 Dimensional Barcodes Portable Data Base n Formats n – – n Stacked Matrix PDF 417 – – – stacked code up to 2000 characters error correction Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State 2 D Barcodes (cont. ) n Data Matrix – – – n matrix, up to 500 characters, error correction scaleable down to. 001 in square marking small items – IC’s, single dose meds Maxicode – – – matrix, 93 characters, error correction 1 inch square, locating bullseye package sortation and tracking Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Bar Code Readers n n handheld or fixed mount contact wands (pens) – n laser scanners – – – n slow, inexpensive longer distance scanning fixed or handheld can read stacked bar codes image scanners – – fixed or handheld can read stacked bar or matrix codes Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Cards n magnetic stripe – – – n low cost low storage capacity contact reader can be rewritten easily damaged (less easily for high coercivity stripes) example: credit cards, bank cards Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Cards (cont. ) n “smart cards” – imbedded microchip n memory only – stored value cards n microprocessor – – – n high storage capacity can be rewritten can execute programs example: some credit cards Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Radio Frequency Tags n n n transponder (tag) is programmed with information reader has an antenna which sends radio signals to activate tag, read or write it types of tags – active (has battery) n – read and write passive (activated by reader) – often read-only n noncontact, non line-of-sight Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State RFID Applications railroad cars, commercial trucks n automobiles on assembly lines n parts carriers in hazardous environments n toll collection on highways n theft prevention in retail n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Why RFID? n tags can be used in harsh conditions – n n n usually housed in protective packaging tags can be read over distances greater than 90 feet tags can be read through snow, grime, cutting fluid, paint, etc. tags can be read at high speed more costly than bar code lack of standardization between manufacturers Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Contact Memory n n n a memory chip in a stainless steel case that resembles a button battery read by touching the case with a probe read only or read-write license plate or portable database additional capabilities can be built in – – – real-time clock temperature sensor cryptography Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Use of Contact Memory asset tracking n access control n digital cash n maintenance records n store manufacturing history for products n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Voice Data Collection hands free n easy to use n must be “trained” to recognize operator n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Some Auto. ID Applications Ford Engine plant n Nabisco warehouse n Ryder trucks n Bigwords warehouse n other applications can be found in: n – – Supply Chain Systems Magazine Modern Material Handling Magazine Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Ford Engine Plant n RFID tags: manufacturing info and test data Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Ford (continued) n n n Essex Engine Plant, Windsor Ontario 700, 000 engines/year, 12 varieties engine work sequence loaded into the tag each station asks tag for its operations test data written to tag source: Supply Chain Systems Magazine Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Nabisco order picking in warehouses n picker logs on by voice n system asks for truck number n system speaks SKU and quantity n picker says “got it” to verify pick n source: Supply Chain Systems Magazine Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Ryder tracks maintenance records on rental vehicles n stores customer name and odometer reading n stores fueling info n contact memory n Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Bigwords. com college textbook e-tailer n key issues n – – – speedy delivery order accuracy peak at start of semester – few weeks source: Supply Chain Systems Magazine Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Bigwords. com Order Flow n order taken on web site – – n n if in stock, order transferred to WMS at the DC else, EDI to publisher, usually ships same day incoming books scanned, add to inventory picking – RF terminals – – – combo pack list/ship label printed formatted for UPS, USPS, etc. pickers take “waves” of labels scan book bar code place in carton, put label on carton scan label to confirm order complete Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Bigwords. com (cont. ) n electronic manifesting system – – n tracks shipment through package carrier does verification scan of label benefits – – speed – up to 25, 000 orders on a peak day high order accuracy, 99. 9% inventory accuracy Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Bigwords. com (cont. ) n how? integration of systems Facility Layout and Material Handling D. J. Medeiros

The Marcus Department of Industrial and Manufacturing Engineering at Penn State Summary n Auto. ID systems provide many capabilities: – – – identify and track products store information about products allow real-time data collection Information is a valuable asset n Auto. ID speeds information flow n Facility Layout and Material Handling D. J. Medeiros