Manufacturing Software Linking Barcode Technology To Quality Control S
ince all barcode technology uses a pictorial representation to relay data to a computer, it is essentially no different from a keyboard. Barcode scanners translate the information and act as a virtual typist inputting data at the rate of 40-200 characters per second. When deliberating solutions to introduce barcodes to the quality con- trol department, manufacturers should consider all points of data entry and the amount of information needed at each step of the quality control process. The data capacity embedded in each barcode varies by the technology used—the standard 1-D 13-digit barcode system can produce ten-thousand billion unique codes, but is limited to the 13 characters of actual data input. Two-dimensional barcodes, such as QR codes, can contain about 100 times more usable information.
In the quality control department, application may be considered at any point in the part program: before, during or after it is run. Before run- ning the program, barcodes can be used on job tickets to encode a variety of traceability information related to that job—part numbers, operator employee numbers, operator instructions, and lot numbers. This informa- tion can be automatically added to input fields on the inspection report to ensure proper recordkeeping. Barcodes could also be used to identify a part program’s filename to ensure the correct inspection routine is run. Metrology inspection software such as PC-DMIS from Hexagon Metrol- ogy (North Kingstown, RI) allows for programmatic data input during an inspection routine and is able to take this information and automatically begin the inspection routine.
During the part program, a company currently using QR codes, or other 2-D barcode technology to label inventory, has the capability of including nominal values as part of the information stored within them. When the individual part or its bin is scanned, the theoretical X, Y, and Z values are instantly pulled. Normally this data is either hard-coded into the software or the operator manually inputs the values. Using barcodes and program input fields, the user interface form can be automatically populated when the code is scanned.
This feature is beneficial to a facility that has several new parts that require parametric programming. Previously, the operator had to manually enter each new nominal value before the program was run. Now the values can be entered into a spreadsheet which is then copied and pasted into a barcode generating program. The resulting barcode is affixed to the part’s bin and contains all required information, as well as the identification of the parts program. A scan of the barcode uploads the data to PC-DMIS and the inspection routine begins automatically. Parametric programming is a part programming technique that
can be used when a “family” of parts exists. The family could fit a set of parameters, for example, all parts are the same shape but differ- ent sizes or the same casting with different hole patterns. One master
inspection plan is created and can execute a variety of measurement tasks based on parameters that are entered during program execution. The program can be branched or parametrically adjusted via data input which could either be manually entered by an operator or scanned via a barcode reader. Parametric programs often use a customized graphi- cal user interface to simplify operation and increase efficiency and accuracy. Employing barcode technology in this instance would input all the necessary data without any user involvement other than scanning the barcode when prompted.
Report shows measurement results based on part parameters executed during an inspection routine.
After the part program is run, barcodes may also be placed on
the parts themselves, using labels or pin stamping for example, to include information on measured features. If a concern surfaces at a later date, the component may be scanned and the original mea- surement information will be revealed. Because of the original data integrity, the scan can also break information down to trace the mate- rials, lots, vendors, machinery, and employees involved with the part’s creation. This is particularly beneficial to the aerospace, automotive, medical or energy industries, where traceability must be documented for safety and recall purposes.
Using barcode technology throughout a manufacturing or assembly facility makes good business sense, and it has been widely used in supply chain management. For companies using barcodes to track inventory, it is a small step to carry it through to their quality control department. Since each facility is unique, expert consultation should be the first step in discussing the potential upgrade. For example, Hexagon Metrology’s ap- plications services group has expertise in barcoding hardware technology, user interface programming, parametric part programming, and typical application of barcoding to the quality control function is essential to a successful project outcome. For more information, contact Shaun Wissner, Software Specialist, at Shaun.Wissner@hexagonmetrology.com.