Bar
Code Application in Lab Management and Tool Inventory Control System at
By
Dr.
Samuel C. Obi
Dr.
Seth Bates
Dr.
Mohan Kim
Dept
of Aviation & Technology
Introduction
A recent move by the
This paper explains the steps
recently taken at one of
SJSU’s Manufacturing Systems Lab
Resources Configuration: A Systematic Approach to Initiating TIC and Bar Code
Implementation
At SJSU’s
Manufacturing Systems laboratories, the development and implementation of a new
resources management system began with a comprehensive but creative approach.
In planning for a TIC system implementation, it is crucial to first consider
such steps as grouping and categorizing laboratory resources, developing a
to-be laboratory layout, generating a tool inventory and matching tools with
proper cribs, and training students and other instructors on how to use the
system. After these steps are concluded, then a TIC system could be
implemented.
Grouping Lab
Resources
Grouping and categorizing the
laboratory’s resources helps in understanding the different categories of
resources that should be managed. It also helps to simplify the task of
organizing the entities into their unique categories. The grouping particularly
facilitates the development and management of inventory control systems in a
laboratory environment, because a TIC system can be implemented for the sole
purpose of managing hand tools, measurement instruments, materials or machine
tools. Because inventory systems are designed with different and distinctive
features for special applications, the grouping helps the technical manager to
select the best system for each category. In this paper, only the management of
tools and instruments are emphasized.
Developing
Lab Layout
The
development of a laboratory layout must be carefully undertaken to represent
what the laboratory has been planned to look like. The objectives of a lab
layout, such as, minimizing material
handling, facilitating manufacturing processes, making economical use of
building space, and fostering students’ convenience, safety and comfort in
doing their projects must be incorporated. (Amrine,
Ritchey, & Moodie, 1987) It particularly helps
lab users to easily and conveniently locate items, by giving users a mental
picture of where those items are located. The layout of the laboratory floor
plan also provides an aerial perspective of the lab, so students can easily
locate specific machines, tool cabinets and cribs. It can also be used as a
reference map to place particular tools and instruments in their respective
locations.
Since the layout visibly shows where the laboratory’s main
entities are located, a legend is used to clarify entities such as machines,
tool cabinets, tool cribs and so forth. Entities like milling machines can be
indicated in blue, tool cabinets and cribs in white, and so forth. All tool cribs
and cabinets are numbered to aid users in determining which particular one
contains the item being sought. Copies of the layout are posted at various
locations in the lab where students and instructors can easily see them. Lab
users can easily identify each component by matching the color of the component
with its associated box in the legend.
Finally, all lab users must be
informed and trained on what has been implemented. All instructors (especially
part-time instructors) who use the lab should be informed about the new
developments and, where applicable, how to use them so they can relay the
information to their students. All instructor colleagues must be informed that
for the plan to work, it is very important that students are trained on how,
why and where to find and return these tools and instruments after using them.
Implementing
a Tool Inventory Control System: A New Paradigm
But even with all the
above improvements, traditional tool management system (which is basically a
tool crib, attendant(s) and manual information entry etc.) is too laborious and
prone to mistakes. It also wastes time, results in carrying too much inventory,
and can cause unnecessary spending on tools, which can be as high as 30% or
more. (Hogan, 2000) As a result of this, many metalworking companies
(especially the big ones) with ever expanding files and literally thousands of
cutting tools are opting for a system that not only facilitates the management
of their tools, but also integrates the database with other company systems.
According to Hogan (2000) such a system provides full information on tool
allocation, availability, usage, cost etc. Such a system also provides a
tracking capability and tool quality support efforts in quality standard
requirements.
One major improvement, which is currently underway, is to
replace all 26 tool cabinets in SJSU’s Manufacturing
lab with one tool room and a permanent attendant. All students will have to
check out their tools from the attendant, and return them in good condition
when they are done. This practice will reduce the somewhat confusing present
placement of tools in 26 storages located all over the lab. The attendant will
use a TIC system and a scanner to check out and check in tools to students.
Modern
tool inventory control systems provide an easy solution to many manufacturing
challenges. These systems are being implemented in major companies at an
increasing rate. Some companies, perhaps to replace the crib attendant or to
save time, are also installing tool-dispensing machines, where an operator
inputs some code and the required tool is dispensed, much like a soda machine.
Because of these advantages, it is anticipated that
Factors to be Considered in Selecting a Tool Inventory Control
System
Generally, one of the most
important factors which users consider before making a purchase is the cost.
Although price should not be the only determining factor when buying software,
most users still consider the affordability of a product before buying it,
especially in a time of limited resources, which many educational programs are
currently experiencing.
Most software
users today expect an easy-to-use or a user-friendly system. Days are gone when
software vendors could easily sell intimidating computer systems to their
customers. Today, almost all users demand simple and easy-to-use systems to
avoid spending extra time and money in training themselves learning how to use
a system. Therefore, ease of use of a system should be considered when planning
for a TIC system.
Since most laboratory tools are discrete items which need to be traced and located, the tracking capability of the system needs to be known before its purchase. Tool inventory control systems are designed for different applications. While some are designed to track discrete, non-perishable items like hand tools, others are designed to track expendable items such as screws and manufacturing materials. Even when they are designed exclusively for tracking discrete, non-perishable or perishable items, the user is still faced with the problem of determining the nature and characteristics of the items to be tracked. For example, while hand tools may not need to be calibrated before checkout, measurement instruments may need to be calibrated. Similarly, while most lab equipment may need a maintenance schedule, manufacturing materials, parts and supplies may not.
Therefore, potential systems
should be studied to determine exactly what each system is designed to do, and
matching that function with the user’s needs, before making the expenditure.
Related to the trackability feature is whether the system has barcode
compatibility. The barcode feature of a TIC system makes it possible for items
to be easily scanned during check-out and check-in, without the use of manual
data entry, which is slow, clumsy and prone to mistakes. Very often, it is also
ideal to have a portable scanning system. The portability of the system makes
it possible for operators to walk to remote locations in the lab, factory or
shop floor and scan items there without having to do it at the crib. Also, when
items to be scanned are too heavy to be moved around, the barcode scanner can
be taken to their location instead.
Most systems
also are capable of generating different reports on specific items, such as on
tool status report or available material quantity at any given time. These
reports are particularly useful when the attendant needs to send the
information to remote locations, or when it is necessary to inform a user of a
missing item that it was due and needed to be returned.
Some, if not
all, users will like to know when the quantity of an item has reached a certain
point so that a new order can be economically made to replenish it. For such
users, the economic order quantity (EOQ) option of the system is a necessity.
This will allow the TIC system to automatically sound an alarm whenever a
preset point is reached.
Lastly,
because many users like to keep their systems upgraded to keep up with the
latest version of the product, the possibility of future upgrade should be
mentioned. Purchasing a TIC system with future upgrade in mind not only ensures
its longevity but also will help users to keep up with the future technological
upgrade of the system at perhaps little or no cost to them
Description
of the Operation of the TIC System and Barcode Scanner
The TIC system purchased at SJSU
is called Tool HoundTM by Houndware
Corporation. Tool Hound is particularly designed for the tracking tools,
supplies, and equipment. This system is used for minimizing human operation
involvement in TIC by utilizing barcodes for employee badge, tool
identification number, part number, location, etc.
The barcode is an array of
differing width parallel bars and spaces. The ordinary bar code is a single
dimensional technology- only the width of the bars and spaces contain
information. The bar height allows
vertical redundancy by providing many possible scanning paths, only one of which
needs to be without imperfection.
We have purchased Welch Allyn’s Imageteam 3800 hand-held
linear imager for scanning device.
Scanners are classified largely by hand-held scanners and fixed location
scanners. Within these categories are
variations depending on the light source and wavelength of light implemented,
whether they are contact or non-contact, and in the case of fixed-location
scanners, whether the beam is a fixed, raster, or omni-directional.
Many or all of these parameters
need to be addressed in selecting the most suited scanner for the
application. System elements are
interactive: a decision concerning one component has an impact on other
elements. For example, if you want to
print with a direct thermal printer, you can’t use an Infrared (IR) scanner,
since most thermal papers do not scan well with the IR wavelength (780-940
nanometers). IR scanners are better suited
for use with labels generated by a thermal transfer printer with a carbon
ribbon. IR scanners can read a carbon-
based barcode obscured with vegetable dye, common in high security codes. The vegetable dye prevents the barcode labels
from being reproduced or photocopied.
Barcodes
stand out as an attractive technology.
They are inexpensively printed by a variety of techniques that offer
high data security. A wide variety of
reading equipment is available to suit all imaginable applications. High
performance fixed scanners can read barcode symbols from a distance of several
feet from an object moving hundreds of feet per minute with relatively lower
cost. Because of the simplicity and
inexpensive application to variety of markets from retail to highly integrated
manufacturing, barcode technology has become the dominant identification
technologies available today
Implications
for Manufacturing and Industrial Technology programs
Manufacturing Systems graduates
are technical, management-oriented personnel who have been exposed to the world
of manufacturing resources (such as tools, materials and instruments) throughout
their preparation at school. Therefore, providing a technical education that
also includes tool inventory control system is an important step in equipping
these graduates for responsible job performance when they graduate and work in
such environments. Since many, if not most, of them eventually graduate and
work in a factory setting, training them in proper laboratory resources
management techniques while at school is a good way to prepare them for their
expected position as middle-level technical line managers. In other words,
exposing students to TIC system environment helps to
prepare them for their expected positions.
Because TIC systems can be a useful part of technical instruction, it is
strongly recommended that lab management of students who do a significant
portion of their academic work in the lab be incorporated into their grade at
the end of the semester. For example, each student who takes a lab course could
manage (check-out and check-in) the lab’s resources using the TIC system for at
least one day during the semester. This practice, while helping them to learn
the names of those tools and instruments, ensures that all the resources are
accounted for and located after the day’s lab session. This will particularly help instructors to have updated information on all tools.
Finally, tool inventory control
systems help tool managers (and manufacturing systems majors) to have updated
information on all tools, a key factor in tasks like locating a missing tool,
accounting for broken tools, knowing when to condition (sharpen) a tool,
knowing when to purchase new tools, maintaining important files on tool
calibration data and such like. Herko (1999)
emphasized that tool management systems add value to manufacturing operations
by supplying information about how tools are used, reused, reworked, and
maintained. He also explained that they capture information about tool usage,
consumption, and usage patterns as well as track tooling all of which will be
beneficial to manufacturing systems programs. The list of the type of
information to be stored in a tool inventory control system is endless. The
systems are so broad that the needs of each user manufacturer or laboratory can
be served adequately.
Conclusion
Laboratory resources are an
important component of manufacturing systems programs. Students who major in
this important program should be informed on current management of key
resources employed in their technical field of study, using modern systems and
techniques such as TIC systems.
This paper shows that
a TIC system with its accompanying scanner can not only save students and
faculty a significant amount of lab time, but also makes running a
manufacturing lab and keeping inventory more efficient. It is also in line with
current industry practice.
References
Amrine, H. T., Ritchey, J. A., & Moodie, C. L. (1987).
Manufacturing Organization and
Management, 5th. Ed.
Herko, F. (May,
1999). Adopting an
Production.
Hogan,
B. J. (Editor) (May, 2000) Tool Management System Pays Off. In Manufacturing
Engineering, volume 124, number 5. Pp
157-160.
Krar, S. F., Rapisarda, M., &
Check, A. F. (1998). Machine Tool
and Manufacturing
Technology.