The lean manufacturing model has been proven and widely adopted in supply chains globally. While the principles are typically implemented in large-scale manufacturing, we can also apply them to optimize our printing and coding operations, ensuring efficiency, simplicity, and cost-effectiveness. Let’s begin.

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1. Coding Errors

Errors in coding result in significant time and financial losses. Inaccurate placement, unreadable codes, and coding mistakes lead to rejection or rework. Additional expenses arise if products with incorrect codes enter the supply chain. Product recalls can incur substantial costs and jeopardize multi-million-euro contracts with clients. Fines may also be imposed. Ensuring the correct code is printed on the right product, in the right location, and in the right manner is crucial. Codico offers solutions to address these challenges. Firstly, our integrated QuickDesign software simplifies batch coding management with templates that minimize data entry, automating print runs through a user-friendly interface and a central database, reducing the risk of human error. Secondly, our automatic print inspection systems swiftly scan each product on your line, minimising the chances of coding errors, ensuring code consistency, speed, and accuracy, and reducing the risk of illegible codes and false rejections, which can save thousands of euros in busy production environments.

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2. Unnecessary Processing

Due to the severe repercussions of coding errors, many manufacturers may become overly vigilant in manually inspecting codes during a print run. However, this approach is inefficient in terms of both time and human resources. Human errors are inevitable in code checking, with an estimated ten mistakes occurring for every 600 coding entries by a human operative. High-speed, high-volume Fast-Moving Consumer Goods (FMCG) lines, such as canning lines operating at speeds of 2,000 cans per minute, are particularly prone to mistakes. If a line operative checks the accuracy of a code on a can every 30 minutes, it essentially means checking one can in every 59,999. This setup increases the likelihood of coding errors slipping through undetected. Implementing automatic print inspection addresses this issue by eliminating errors and allowing the redeployment of human resources to other areas of manufacturing. Another instance of excess processing lies in manually monitoring printer fleet efficiency. With the advent of Industry 4.0, technology now exists to automatically collect data on printer performance and transmit it to the cloud. This enables a dashboard view of the printer fleet, facilitating continual improvements in line efficiency.
Examples of print coding errors during manufacturing

3. Overproduction

Unnecessary manufacturing processes, particularly in the context of applying codes to packaging where the quantity of printed labels must align with the production volume, can hinder the lean manufacturing model. You can enhance the efficiency of code production and print run management through QuickDesign. Additionally, our array of print and apply technologies can reduce the time required for manually applying labels to secondary and tertiary packaging. Our print and apply labelling systems are adaptable, dependable, and robust. Whether they are tasked with affixing labels to individual product fronts, tray tops, or bundle package corners, they fulfill all requirements for traceability, legibility, and clarity.

4. Waiting

As the saying goes, time is equivalent to money. This holds true for coding and marking, just as it does in any other business domain. Therefore, it’s crucial to eliminate unnecessary delays from your processes. Delays may arise from printer failures, mechanical downtime, excessive scheduled maintenance, and integration issues within your coding and marking infrastructure. Domino specialises in dependable technology. We also provide a range of Service Packages designed to minimise downtime, extend warranties on parts and labor, and ensure your printer operates at peak performance, safeguarding your production Overall Equipment Efficiency (OEE). Monitoring your printer remotely, with automated alerts and performance data analysis, can aid in detecting and addressing issues before they escalate. In the rare event of a necessary service call, our engineers respond swiftly, equipped with the necessary knowledge about the equipment they’re attending to.

Monitoring printer performance remotely and analysing performance data

5. Inventory

Challenges and inefficiencies may arise when managing multiple concurrent print runs. Domino’s printing technology ensures rapid and accurate processing of products through your production environment, avoiding any backlog. The flexibility provided by QuickDesign allows for swift responses to situations such as seasonal promotions, enabling late-stage customization of your product coding and marking.

6. Transportation

Essential components like ink cartridges are integral to most coding and marking technologies. However, on-site stock is typically limited to prevent expiration or unintended usage of the materials. This limitation can result in delays while waiting for stock availability for your next production line use. To enhance efficiency in the restocking process, Domino’s SafeSupply service enables you to schedule delivery dates for genuine Domino consumables, ensuring accurate coding and efficient printer performance. Additionally, we offer fixed pricing for your consumables for up to five years, allowing for accurate budgeting.

7. Motion

In larger printing technology networks, manufacturers may encounter additional inefficiencies. Poorly designed operational layouts can lead to challenges in the movement of products through production lines, exacerbated by disconnected infrastructure. We can offer guidance on optimizing your production environment for streamlined coding and marking operations. Leveraging the QuickDesign platform, you can achieve operational harmony by translating the language of your ERP or MES into the Domino language. The outcome is a connected and highly efficient operational framework with remote label design capabilities, reducing operator involvement and enabling on-demand transmission of the correct coding commands to any printer in your network.

8. Non-Utilised Talent

While it’s common to concentrate on processes or machinery when pinpointing manufacturing inefficiencies, the human aspect of operations is equally crucial. Insufficient training can lead to unnecessary delays or halts on the production line, and untapped staff potential or undeveloped key competencies can result in mistakes. Domino’s training academy is designed to provide your staff with the technical insights necessary to maintain efficient coding and marking operations. Training can be conducted in person or via webinars, ensuring your staff is knowledgeable, engaged, and equipped with the information needed to optimize your printing fleet. Additionally, our printing and coding solutions offer a high level of automation through automatic print inspection or Domino Cloud, our remote diagnostic technology as part of the SafeGuard support package. By training staff on this Industry 4.0 technology, they become empowered to contribute to predicting future technology failures and downtimes, thereby eliminating under-utilized talent.Domino training academy running a technical insights course

What’s on the Horizon?

Conducting a thorough assessment of your coding and marking operations enables you to pinpoint inefficiencies, leading to time and cost savings and providing an opportunity to engage and enhance the skills of your human resources. However, overcoming the unique challenges at your site is crucial for success. Codico is here to assist. Reach out to us to initiate the conversation.

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