Background/Problems
In some cases traceability needs to extend to serialised parts. These parts are usually critical in some way for example high value items, critical functionality or safety critical. In this case, the serialised parts may come in from suppliers or may be produced in production as semi-finished goods that are operated on or consumed in later operations.
The requirement is to track all aspects of their production, from when it was operated on at a work centre, to what materials were used – either the serial number of critical parts or lot traceability.
Solution
The Build Traceability module of Shopfloor-OnlineTM Lifescience Edition is able to record all traceability information at a serial number level of each part as it is used or assembled into the line or machine. It captures:
- The serial number of the parts being made and used or assembled. It can read from a bar-code label or RFID tag.
- The date and time that the Part went through each step in the process.
- The machine or step in the process. So for example if through the process there were several machines in parallel that could perform the same operation, the build record records the actual machine that built this part.
- The pack identifier and quantity of each component that was assembled into the part. This could be a unique component (e.g. the serial number of the major subcomponent), or it could be the batch number that applied to numerous components (e.g. solder paste in an electronic assembly process).
- Automatically additional information like who loaded it, the Production Order, etc.
- The serialised materials and validates they are correct against the materials specified in the BOM
- Links with the ERP system to inform the quantities of actual materials consumed rather than the more traditional back-flush methods.
When Used with Other Modules
When the Build Traceability module is used in conjunction with other modules of Shopfloor-OnlineTM Lifescience Edition more opportunities open up. For example:
- Inventory: all inventory is known before the point of consumption and so can be validated at the point of use. Checks can be made in terms of the material state – you can’t consume material that has been isolated; aging criteria i.e. best before date, use after date.
- Traceability – Consumption: works in the same way as Build Traceability and allows lot numbers of materials to be consumed and recorded against the serialised part production.
- Quality module: record the results of quality checks against individual packs (or serialised parts), increasing traceability to each individual pack.
Benefits
- Serialised traceability – Extend the traceability capabilities by tracking serialised parts made and the serial numbers of parts produced.
- Detailed traceability – track each serialised item as it passes every point in the process.
- Check materials before they are used – ensure the operators are always using the correct materials in the production process by validating against the BOM.
- Enforce age of materials constraints – in some environments “use-by” and “use-after” dates need to be enforced, Shopfloor-OnlineTM Lifescience Edition checks these automatically at the point of consumption.
- Enforce FIFO rules – many companies want to impose FIFO rules relating to the use of raw materials and work in progress. FIFO rules can be checked at consumption to ensure the correct lot of material is always being used.
- Accurate stock control – optionally update ERP systems of actual stock used, when used, rather than back flushing.
