BarCode ID Systems is proud to spotlight just a few of our application success stories:

Leading Snack Manufacturer Improves Packaging Efficiency and Cuts Costs with On-Demand Carton Labeling
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Cape Cod Potato Chips, the leader in popular kettle-cooked potato chips in the United States, produces 37 different varieties and sizes of snack flavors at its manufacturing facility in Hyannis, Massachusetts. All Cape Cod’s chips are cooked in small batches and case cartons are hand packed at the end of the production lines. For every variety and size of snack product, Cape Cod was purchasing preprinted labels for case marking. They wanted to move away from the expense and inventory problems of preprinted case labels and enable label printing at each individual packaging line.

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The Challenge:
At Cape Cod’s Hyannis, Mass. manufacturing facility, over 80,000 packages of snacks are made daily. Despite this production volume, all cases of snacks are packaged by hand and manually labeled with the appropriate case label denoting the product enclosed, individual package size, weight, SKU, quantity, etc. Cape Cod had been purchasing and using preprinted labels for every one of the numerous chip varieties and sizes they produced, which caused several challenges: first, the preprinted labels were expensive; secondly, inventory of the preprinted label stock was cumbersome to maintain and manage. Labels were kept in a various storage rooms where line workers would have to go to retrieve rolls of carton labels for the particular line of snacks they were packaging that day. Workers could easily find themselves in a low- or out-of-stock situation if label stocks were not replenished properly, and labels were also frequently misplaced or difficult to find. Additionally, because of the volume of preprinted labels needed and the space limitations of the manufacturing facility, the labels were stored in three different areas, some of which were not climate controlled—thus resulting in inconsistent adhesion. Labels in non-climate controlled environments could ; thirdly, Cape Cod found itself placing label orders weekly to avoid inventory shortages, thus adding to the already high cost of preprinted labels; lastly, roller stamps were used to add date-sensitive production information to the preprinted labels, frequently resulting in misaligned text, incorrect fonts and color differences. Cape Cod wanted to take control of carton labeling on its eight production lines to increase worker productivity and eliminate all of the issues associated with preprinted labels.

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The Solution:
BarCode ID Systems provided a complete end-to-end distributed printing solution for Cape Cod Potato Chip that allowed on-demand printing at the point of activity. As a Premier Partner with Zebra Technologies, BarCode ID Systems installed and configured Zebra® 140XiIIIPlus printers with Ethernet connectivity for each of Cape Cod’s production lines throughout its entire facility. BarCode ID Systems’ Professional Services team connected each printer to Cape Cod’s LAN for controlled TCP/IP printing by production supervisors during each shift, and trained Cape Cod staff members on printer configuration, use and features. BarCode ID Systems also provided all printing supplies and included annual on-site service contracts for repair and maintenance protection on all Zebra printers.

To drive the printing solution, BarCode ID Systems’ Professional Services team provided LabelVision® 20/20 software, a robust bar code labeling program with a powerful built-in database. For initial database population—and for subsequent, periodic updates—data was imported from Cape Cod’s SAP-generated data file to ensure that the printed data contained correct product information for proper label printing. The LabelVision database allowed correctly-formatted label printing even if the SAP system was off-line for any reason such as routine maintenance during third shift operations. The LabelVision database also allows for easy re-integration if Cape Cod every changes from SAP to another ERP system.

Labels templates were designed to reduce the number of label files and to ensure consistency of label appearance between every variety and packaged size of Cape Cod’s snacks. Use of LabelVision’s integrated Menu Editor allowed for simple label selection and staff members were fully trained on software operation. During production, shift supervisors would send batches of appropriate labels to each packaging line from a central network PC, thereby eliminating the need for line workers to go to the storage room to retrieve rolls of preprinted labels. Printers at all stations were set to run in peel-off mode, where single labels were printed and held until the line workers were ready to apply them. Workers on each line would hand pack every case carton then take a label from the printer and apply it to the carton, which then moved down the line for taping and palletizing. When a label was taken from the printer, the printer would then generate and hold another label from the batch.

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The Results:
BarCode ID Systems provided an integrated production line printing solution for Cape Cod Potato Chip’s manufacturing operation. The Zebra 140XiIIIPlus printers with external printservers provided Cape Cod with the high volume, rugged performance they required on their packaging lines and enabled them to completely eliminate the high costs and associated problems of using preprinted labels. By using one size blank label printed with variable data from SAP using LabelVision 20/20 software, Cape Cod was able to reduce inventory costs, decrease man hours previously needed to manage and order preprinted label inventory, and free up a considerable amount of storage space. With the proper carton label presented to line workers from individual printers, line worker efficiency was increased. Spare printers ensured that Cape Cod’s carton labeling lines would run without significant downtime, and the use of external printservers would allow Cape Cod to quickly swap a faulty printer with a spare unit without having to do any configuration. Annual printer service coverage also provided for factory-authorized repair services and proper maintenance of line equipment.

Since 1980, Cape Cod Potato Chips has led the potato chip category in the marketing of old fashioned kettle-cooked potato chips. Celebrating its 23rd anniversary, Cape Cod has grown from making 200 bags a day to producing 150,000 bags a day – each kettle-cooked, one small bag at a time. Today, Cape Cod’s potato chip line has expanded to include Classic, Russets, Reduced Fat and the Whole Earth Collection. The company also makes a full line of tortilla chips, popcorn, pretzels and other snacks. Cape Cod Potato Chips is a Division of Lance Companies. More information on Cape Cod Potato Chips is available at www.capecodchips.com.

BarCode ID Systems is a bar code systems integrator, mobile computing specialist and RFID solution provider. Privately owned and headquartered in Atlanta, Georgia, BarCode ID Systems focuses on data automation solutions for manufacturing, distribution and healthcare environments, specializing in the automotive, electronics, food/beverage, pharmaceutical, life sciences, paper/plastics, textile and retail industries. With sales and engineering offices in the Southeast, Midwest and Northeast, BarCode ID Systems provides internal and external data management solutions for the growing mobile enterprise. BarCode ID Systems is an authorized Symbol® Business Partner, Zebra® Premier Partner, Microscan® Preferred Partner and Intermec®Honors Partner.

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Transportation Company Improves Inventory, Put-Away and Shipping Efficiency with Mobile Printing
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As a service-oriented transportation corporation, Smith Transport provides a variety of transportation and logistics services to clients across the country, including traditional truckload movements, dedicated truckload services to customer deferred points, consolidation of customized LTL movements, short and long-term storage, real-time inventory control and other specifically tailored services to meet unique customer requirements. Smith Eagle Logistics, an Operating Subsidiary of Smith Transport, is a full service provider of Integrated Third Party Logistical Services with a specialty in distribution and load consolidation methodology. At its logistics warehouse in Tyrone, Pennsylvania, Smith Transport was labeling hundreds of pallets daily from a central printing station, resulting in mislabeled, misplaced and poorly-handled product. Smith Transport needed to improve efficiency, product handling and tracking.

The Challenge:
At its 450,000 sq. ft. Eagle Logistics facility in Tyrone, Pennsylvania, Smith Transport receives 600 to 800 pallets per day through 45 dock doors. When inbound pallets are received, Smith’s warehouse management system generates new product routing or storage labels to track pallets within the facility. Fork-lift operators would put the pallets away, then return to a centralized printing station where the new labels were printed, then go back to the pallet location and re-label the products for internal tracking and outbound distribution purposes. Inefficiencies in time management and errors in re-labeling the pallets were causing increased problems for Smith Transport. Incorrectly-labeled pallets would be mis-directed, mis-shipped or lost in the system. Smith needed to streamline their receipt of products, labeling and put-away.

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The Solution:
BarCode ID Systems provided a complete mobile printing solution for Smith Transport’s warehousing application, furnishing them with wireless printers, media and annual depot service coverage for their mobile printers. BarCode ID Systems installed 15 Zebra® QL420 mobile printers with 4x6 direct thermal labels for use by warehouse fork lift operators who could then label pallets properly at the point of receipt, before product was put away. Using the QL420 printers connected to Smith Transport’s Wireless LAN, operators would re-label pallets immediately with internal routing/license plate labels, virtually eliminating mislabeled pallets. BarCode ID Systems also provided full depot service coverage for all Zebra printers to ensure Smith was protected when printers required maintenance or repairs.

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The Results:
BarCode ID Systems provided a total mobile printing solution for Smith Transport’s logistic warehouse operation. The QL420 mobile printers increased operator efficiencies, improved material handling times and decreased rerouting problems. With operators printing identification labels at the point of put-away, Smith Transport was able to avoid the confusion and errors of applying labels to pallets as a secondary step or function. Since system implementation in the summer of 2003, Smith Transport has seen a significant reduction in mis-labeled and mis-handled pallets, considerable gains in fork-truck putaway efficiencies and a significant reduction in labeling errors. By implementing a mobile printing solution in their warehouse operation, Smith Transport has improved warehouse accuracy, reduced mishandled freight costs and improved operating efficiencies.

Smith Transport is a Pennsylvania-based Company providing a complete line of Logistics Services to businesses located throughout the Continental United States and Canada. Smith Transport and its Subsidiaries are uniquely postured to provide a Totally Bundled and Customized Third Party Logistics Package(s) or Individually Tailored Service Offerings to meet the precise needs of the Customer.

BarCode ID Systems is a bar code systems integrator, mobile computing specialist and RFID solution provider. Privately owned and headquartered in Atlanta, Georgia, BarCode ID Systems focuses on data automation solutions for manufacturing, distribution and healthcare environments, specializing in the automotive, electronics, food/beverage, pharmaceutical, life sciences, paper/plastics, textile and retail industries. With sales and engineering offices in the Southeast, Midwest and Northeast, BarCode ID Systems provides internal and external data management solutions for the growing mobile enterprise. BarCode ID Systems is an authorized Symbol® Business Partner, Zebra® Premier Partner, Microscan® Preferred Partner and Intermec®Honors Partner.

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The Greenville Chapter of the Salvation Army sponsors a Christmas Toy Distribution for needy families in Greenville, South Carolina. Bags of toys and BiLo food certificates that have been donated by local area businesses and individuals are packaged and distributed to families who have applied for the Christmas Distribution Program. Before the Christmas season 2003, the Salvation Army tracked and distributed all items manually, causing numerous delays, interruptions and obstructions in the distribution process. Spearheaded by Systems Engineer Amber Richards, BarCode ID Systems donated time, equipment and a custom tracking application to assist the Salvation Army with its 2003 Christmas Distribution Program.

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The Challenge:
The Salvation Army’s existing toy distribution system consisted of manual bag identification (a printed sheet stapled to each bag) and bag distribution by a staff of volunteers on “distribution day.” Since the manual system did not allow for easy tracking or accountability of the gift bags as they were assembled or distributed, several problems ensued. Missing bags on distribution day required volunteers to prepare additional bags while recipients waited in a designated waiting area (“Trouble Area”); recipients could manipulate the system to receive multiple bags, and bottlenecks in the distribution process caused appointed pick-up times to run more than an hour behind schedule. Volunteers became harried, recipients were angry, and limited toy inventories deprived other deserving recipients of toy bags if replacement bags had to be assembled.

Project Objectives:
The objectives of the project were as follows: 1) label all toy bags as they were assembled, 2) perform a cycle count of all bags prior to distribution day to ensure the correct quantity exists for all intended recipients, and 3) establish an automated check-out system to track bags as they are distributed to the proper recipients. With this system in place, the Salvation Army would have an accurate count of all bags produced and a record of all bags distributed and their recipients. BarCode ID Systems donated all labels for the bags, provided a Symbol PDT6846 RF (radio frequency) handheld computer and 4121Access Point for the cycle counts and distribution, and wrote a custom application for inventory, tracking and distribution of gift bags.

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The Solution:
1) Bag Labeling — All bags were tagged with bar code label(s) after being assembled by volunteers. The bag labels were created with LabelVision® software and consisted of the parent’s last name, the child’s age/gender/ name, the last four digits of an assigned “Christmas Number,” and a bar code with the child’s “Angel Number.” More than one label could be affixed to a bag to indicate gifts for multi-child families, and all bag labels would be scanned during Cycle Count and at Check Out.

2) Cycle Count — All bag labels were scanned on the Saturday prior to distribution day to ensure that each intended recipient would have a toy bag waiting for them on distribution day. Early counting and reconciliation of bags for recipients would reduce the number of people in the “Trouble Area,” where recipients had to go if their gift bags could not be located. BarCode ID Systems provided a Symbol PDT 6846 RF terminal and 4121 Access Point to use during Cycle Count. Every label scan triggered a database lookup for the child’s “Angel Number.” When identified, the record was flagged in the “Check-In” column to indicate the bag had been assembled and was in inventory awaiting distribution.

3) Check Out — On distribution day, all bag labels were scanned at check out before leaving the dock door. Scans triggered a database lookup for the child’s “Angel Number,” flagged the record to indicate that a bag had been distributed and was no longer in inventory, and recorded the information in the master database (Access). If a recipient went Trouble Area with a bag loss claim, volunteers could run a simple database check to determine whether or not a bag had been distributed previously.

4) Reporting — Reports were available as a Microsoft Access database query and included Bags in Inventory/Not Distributed and Bags Distributed.

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Project Update: (click here to download .pdf with photos)
The Salvation Army’s Christmas Toy Distribution was a huge success and received local coverage on the Greenville evening news. The comparison between pervious distributions and this year’s program was staggering. Virtually every participant and volunteer were amazed at how the automated procedures made bag distribution a smooth and efficient process that ran ahead of schedule.

Bag Labeling — Volunteers began packing toy bags for approved recipients on December 1 and continued through December 20, 2003. Bar coded labels were preprinted for each child/recipient and affixed to the bags. Because recipient families often had more than one child, a single bag could contain items for multiple children. In these scenarios, multiple bar codes on each bag ensured that each child had been served and provided the recipients with visual confirmation that each child had items in the bag.

Cycle Count — A cycle count was performed at the end of the last bag packing day (December 20). The cycle count indicated that 27 bags were missing or not yet assembled. Missing bags were listed in a report for volunteers, who then created additional bags before distribution day arrived. Over 1700 bags were ultimately packed and ready for distribution day—December 22, 2003. Some children in the program were eligible to receive a bicycle in addition to their gift bags. These children were required to meet additional application requirements including good school grades, attendance, and behavior.

Check Out — Recipients were assigned a pick-up appointment time and tag prior to distribution day. Two pick-up zones (Dock Drive-Up and Trouble Area) were on or ahead of schedule the entire day. Dock Drive-Up volunteers used CB radios to relay tag numbers to volunteers inside, who then located the correct gift bag(s) and took them to the recipients’ cars. All bags were scanned before leaving the warehouse area.

If the recipient’s bag could not be located, the recipient was directed to the Trouble Area so a bag could be made. Last year, cars were lined up at Dock Drive-Up until past 7:00pm, and many recipients were told that they must go to the Trouble Area after waiting hours in the Drive-UP line. Pick-up appointments were more than an hour behind schedule and recipients were understandably agitated. With the 2003 program, cars arriving for pick-up slowed to a trickle by 2:30pm and pick-ups ended by 4:00pm. All pick-up appointments were on or ahead of schedule.

Last year, approximately 300 people were sent to the Trouble Area where the average recipient waited an hour; some more than two hours. Many times during the day the Trouble Area was standing room only. This year, only about 30 people were seen in the Trouble Area and no one had to wait more than 30 minutes.

At the end of the day (4:00pm), a report was run to show how many bags remained in inventory, allowing Salvation Army personnel to contact the families the following day to arrange pick up. Only 103 recipient bags (66 families) remained unclaimed out of 1,789 total bags.

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The bar coding application and equipment provided by BarCode ID Systems prevented multiple issues and streamlined the entire assembly, inventory and distribution process for the Salvation Army Christmas Toy Distribution. One unforeseen benefit to bar coded distribution was that recipients could see that volunteers were scanning and verifying bags. With such procedures in place, recipients did not attempt to come inside to the Trouble Area first to claim lost tickets.

The Salvation Army's event organizer commented that he knew bar coding would assist in some areas such as cross-checking, but had no idea what an impact it would make on the entire process. Click here to view the Salvation Army’s thank you letter.

BarCode ID Systems is a turnkey bar code system integrator and wireless solutions specialist. Established in 1993 and head-quartered in Atlanta, Georgia, BarCode ID Systems provides supply chain data automation solutions to manufacturing, distribution and life sciences. With sales offices in Atlanta, Greenville, South Carolina, Chicago and Boston, BarCode ID Systems provides visionary solutions, leading edge products, technical ingenuity and industry expertise. BarCode ID Systems is a Symbol Business Partner, Zebra Premier Partner, Intermec Honors Partner and Microscan Preferred Partner. Our core offering includes wireless solutions, bar code printing & scanning systems, compliance labeling, warehouse and inventory management, print & apply systems, ERP interfaces, software solutions and media. Contact BarCode ID Systems at 800-452-7418.

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Coats North America (Charlotte, North Carolina), is part of the worldwide Coats family—the world's largest supplier of industrial sewing thread and craft products. With more than 60,000 employees worldwide, and manufacturing locations in more than 60 countries, Coats is the largest global supplier of sewing thread.

Coats North America required more sophisticated methods of handling its inventory, raw materials and finished goods at 22 manufacturing and distribution centers in North America, Central America and the Caribbean. Additionally, Coats wanted an open-source system for its own IT staff to continue the system implementation once the three pilot sites were completed. To accommodate its Spanish-speaking users in South America, the system also had to be bilingual.

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The Challenge:
Coats North America wanted to replace, enhance and expand its existing inventory management systems at 22 total facilities in North America, Central America and the Caribbean. BarCode ID Systems began initial system implementation at Coats’ manufacturing and distribution facility in Greer, South Carolina, and at two distribution centers in Toccoa, Georgia and Marion, North Carolina. All three facilities had to upload data to an AS400 host at their headquarters in Charlotte, North Carolina. After implementation in these three facilities, Coats wanted to be trained to install the system in their other facilities worldwide.

Coats’ current system had not only outlived its functionality, it was also proprietary, thus prohibiting Coats from making any changes or updates to the system. The system was limited to handle only one warehouse function at a time, it could not produce shipping manifests, and it was not bilingual—all of which were requirements for Coats’ new system. Additionally, Coats was using outdated handheld terminals that were malfunctioning and subject to frequent breakdowns. Coats was suffering productivity problems and labor inefficiencies due to unreliable equipment and an antiquated data collection system.

The Solution:
Coats turned to BarCode ID Systems (Atlanta, Georgia), to begin development of the data collection project in late 2002. BarCode ID presented Coats with a design specification for a batch data collection system, encompassing finished goods put-away, raw material receiving, shipping and inventory, and Coats purchased over 100 PSC Falcon 340 units with integrated laser scanners.

The new system duplicated the functionality of Coats’ existing proprietary system and added desired enhancements in six key areas:

• Receiving of Raw Materials
• Put-Away (Locating) of Finished Goods and Greige Yarn
• Issuing of Raw Materials
• Shipment Verification of Finished Goods
• Inventory (Cycle Count & Physical Count) of Finished Goods, Greige Yarn and Raw Materials
• Shipping Manifests of Finished Goods

The system consisted of a handheld batch application, a PC program with a Windows-based user interface and a Transaction Posting Program. The Transaction Posting Program delivered a fixed-length flat file to the current AS400 system through an automated FTP upload. The flat file system approach desired by Coats would also allow for integration to future systems as well, such as SAP.

One of the most important system enhancements required by Coats was the ability to run reports and review the data for accuracy before communicating it back to corporate headquarters. Previously, Coats’ handheld terminals would send data to corporate that often contained inaccurate information. The host would generate an error or discrepancy report to send back to the users, who would then have to scan the entire order again and resend to the host.

BarCode ID Systems used Clarion to develop an intermediary PC application named CAPR (Coats American Posting & Reporting), CAPR would receive raw data files from the handhelds and populate fields in the SQL server database automatically. CAPR’s user interface would then allow operators to perform Data Edits, where they could sort and review the data, identify errors, make corrections to the orders (without rescanning the entire order) and adjust the system data. Once reports were adjusted appropriately, the CAPR program would automatically return the data to the flat file format required by the AS400 host and upload to the secure FTP server. CAPR also included Report Retrieval functionality (users could sort and print based on timeframe, e.g., all data within the last 24 hours), and Manifest Reporting (group by shipment number, group by product, give totals by product, shipment, etc.) Coats’ existing system did not have any shipping manifest functionality.

Several layers of security measures were also included in the CAPR system. The base level requires no passwords beyond a Windows login and allows users to view lists (uploaded data) and run/print reports. The CAPR administrator login allows supervisors or other management personnel to adjust records (change/add/delete) in addition to base-level activities. The third security level, an FTP login, has its own username and password which are setup and maintained by Coats’ corporate IT department. The file naming convention for the FTP flat file upload also includes the username of the operator who posts the data, which adds accountability for the data being uploaded.

Key Factors and Results:
One key factor with the BarCode ID solution for Coats was that all warehouse program functions could be performed simultaneously. Operators could now toggle between receiving, put-away, shipping and inventory applications within one single program. Previously, the Coats system was comprised of eight separate programs and users had to select and download one desired function while the handheld terminals were cradled and connected to a PC. To change functions, users had to return to the central PC, upload the handheld’s records, select a new function, download the new function and then return to scanning. With the new multitasking operability of the BarCode ID program, user efficiency has been greatly improved.

Another key factor is the bilingual functionality built into the system by BarCode ID Systems, allowing users to switch between English and Spanish language on demand. In the past, the Coats system was English only and only one language could reside on each device.

By November 2003, installations were completed at all three initial Coats facilities in South Carolina, Georgia and North Carolina. The Coats IT staff has been trained to continue roll-out of the system at 19 other facilities in North America, Central America, and the Caribbean, and they have realized significant gains in warehouse productivity and labor efficiency. With the reporting abilities of their new system and the clean data transfers to corporate, Coats’ personnel productivity has increased and labor has become more efficient. Operators save time performing warehouse functions because all necessary applications are accessible immediately on one device, and inventory and shipping accuracy have improved. And, with on-the-fly bilingual access on every handheld device, Coats’ Spanish speaking users have immediate access to all necessary programs without delay.

Coats North America, Charlotte, North Carolina, is part of the Coats Viyella Group based in London, England. As the largest global supplier of sewing thread, Coats North America also manufactures and distributes a wide array of products for home sewing, hand-knitting, and crafts projects.

BarCode ID Systems is a turnkey bar code system integrator and wireless solutions specialist. Established in 1993 and headquartered in Atlanta, Georgia, BarCode ID Systems provides supply chain automation solutions to industries including manufacturing, distribution and life sciences. . With sales offices in Atlanta, Greenville, South Carolina, Chicago and Boston, BarCode ID Systems provides visionary solutions, leading edge products, technical ingenuity and industry expertise. BarCode ID Systems is a Symbol Business Partner, Zebra Premier Partner, Intermec Honors Partner and Microscan Preferred Partner. Our core offering includes wireless solutions, bar code printing & scanning systems, compliance labeling, warehouse and inventorym anagement, print & apply systems, ERP interfaces, software solutions and media.

Avio-Diepen specializes in stock management and spare parts distribution to Airline, OEM, and MRO customers throughout the world. The company’s headquarters in The Netherlands had recently automated their inventory management, but the U.S. facility in Atlanta, Georgia was handling all inventory manually. Additionally, because their U.S. location did not have its own on-site IT staff, Avio-Diepen required a versatile supplier who could provide complete system implementation, installation and training, as well local support.

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The Challenge:
Avio-Diepen Atlanta was handling their entire inventory by hand. With no scanning systems in place, they were faced with shipping & receiving inaccuracies, lengthy put-away times, inventory discrepancies and delays associated with manual data entry. Extra labor from other departments was necessary, on occasion, to perform manual data entry in the warehouse. Additionally, as a global commercial aerospace parts distributor receiving shipments from both the U.S and abroad, Avio-Diepen’s Atlanta location was faced with the problem of extended shipping times and high costs for replacement of international inventory.

The Solution:
BarCode ID Systems provided a complete, turnkey RF solution for Avio-Diepen. In their 20,000 square foot warehouse with a UNIX host, BarCode ID Systems completed a small site survey and installation of two Symbol 802.11b Access Points, all cabling and hard installation. Three Symbol PDT-6846 devices, loaded with VT220 emulation licenses, were used to gain access to the company's Unix host, which allowed for various warehousing transactions—such as receiving, put-away, picking and shipping—and a real time link to the host's database files.

Since all inbound inventory was already bar coded, Avio-Diepen did not have to mark incoming products. However, BarCode ID Systems provided approximately 10,000 preprinted shelf- and floor-marking location labels for inventory management. BarCode ID also provided system training and instruction on the AP and handheld device configuration, as well as a one-year service contract on the equipment.

The Results:
BarCode ID Systems provided a total solution for Avio-Diepen’s data automation project. Since system implementation in August 2003, Avio-Diepen has benefited from significant improvements in inventory accuracy and reconciliation. Put-away times have decreased and efficiency gains in picking and shipping have been realized. With the complete elimination of manual data entry, labor costs have decreased and additional personnel resources are no longer needed in the warehouse. Additionally, Avio-Diepen’s improved inventory accuracy has reduced the costs associated with lost or misplaced product and eliminated the need for emergency product replacement from overseas.

Avio-Diepen specializes in stock management and spare parts distribution of factory new certified components to Airline, OEM, and MRO customers throughout the world. With offices and distribution centers in the Netherlands, the United Kingdom, the United States, Hong Kong and China, Avio-Diepen helps customers reduce direct and indirect costs by reducing lead-times, consolidating suppliers, implementing strategic supply chain management initiatives, and offering PMA alternatives.

BarCode ID Systems is a turnkey bar code system integrator and wireless solutions specialist. Established in 1993 and headquartered in Atlanta, Georgia, BarCode ID Systems provides supply chain automation solutions to industries including manufacturing, distribution and life sciences. . With sales offices in Atlanta, Greenville, South Carolina, Chicago and Boston, BarCode ID Systems provides visionary solutions, leading edge products, technical ingenuity and industry expertise. BarCode ID Systems is a Symbol Business Partner, Zebra Premier Partner, Intermec Honors Partner and Microscan Preferred Partner. Our core offering includes wireless solutions, bar code printing & scanning systems, compliance labeling, warehouse and inventory management, print & apply systems, ERP interfaces, software solutions and media.

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Textile Manufacturer Improves Scan/Print System with Automated Print & Apply
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As one of the leading textile manufacturers and distributors in the southeast, Dillon Yarn Corp., (Dillon, SC), was faced with increasing production problems due to antiquated equipment and obsolete technology on their conveyor lines.

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The Challenge:
As a manufacturer running three shifts per day, seven days per week, Dillon’s productivity was decreasing due to printer downtimes. Their printing equipment was unreliable and suffered an increasing number of breakdowns and print quality issues, which caused line backup, manual intervention on the conveyor, and false or poor reads by the scanners. Additionally, repairs on their discontinued printers were becoming increasingly difficult due to the inability to get parts. Because Dillon’s scanners and homegrown software systems were functioning well, they only wanted to upgrade their printers & label applicators. Any new equipment had to integrate smoothly with their existing system and scanners.

The Application:
In Dillon’s facility, boxes of finished yarn spools are packaged and hand labeled with product lot numbers, then sent down one of three conveyor lines to be taped, weighed, labeled and directed for distribution.

Each line contains two Accusort fixed-mounts scanners and one Printronix T1006 tabletop thermal transfer printer, modified with an external add-on applicator. The first scanner scans the product lot number, prompting a lookup in the AS400 database for information to include on the 6” x 8” product ID label to be printed further down the line, including Lot Number, Description, Color, Quantity, Inspector, Gross Weight, Net Weight and a Supplier ID number. The box is then weighed on an integrated scale and moved into position to be labeled.

When the box reaches its exact position to be labeled, a photo eye triggers the conveyor to come to a complete stop. The conveyor must stop immediately, with no residual movement, due to the small (125” to .25”) tolerance for label placement. Label position is vital because the product ID information will be scanned further down the line by the second Accusort fixed-mount scanner, which directs the boxes to the correct point for put away in the finished goods warehouse. The Accusort scanners are straight-line lasers, not rasters, so label placement in this application is key for proper scanning position.

The Solution:
BarCode ID Systems replaced the aging and obsolete Printronix printers and homegrown applicator systems with Paragon automated print & apply label applicators with Zebra 170PAX3 300dpi print engines and heavy-duty tamp label cylinders. The label applicators were integrated into the line and connected to existing PCs that receive product ID data and weight from the line’s Primary Logic Controller (PLC) and send label formats and print signals to the applicators. Additionally, output relays on the Paragon applicators were set to trigger a signal to the PLC to restart the conveyor after labeling was complete.

The Results:
Dillon realized improved line results immediately after the new equipment was in place. The clean, quality print from the Zebra PAX engines eliminated all scanning errors after labels were printed, and their ruggedness and reliability has virtually eliminated printer downtime and maintenance issues. Line productivity has increased with the new equipment in place, and manual intervention on the conveyor due to printer downtime or scanner misreads as virtually been eliminated.

Located in Dillon, South Carolina and established in 1968, Dillon Yarn Corp. is a division of Titan Textile Company, Inc., (Paterson, NJ). Privately owned and one of the largest employers in South Carolina, Dillon Yarn manufactures and distributes textured polyester yarn to industrial and consumer goods manufacturers.

BarCode ID Systems is a turnkey bar code system integrator and wireless solutions specialist. Established in 1993 and headquartered in Atlanta, Georgia, BarCode ID Systems provides supply chain automation solutions to industries including manufacturing, distribution and life sciences. . With sales offices in Atlanta, Greenville, South Carolina, Chicago and Boston, BarCode ID Systems provides visionary solutions, leading edge products, technical ingenuity and industry expertise. BarCode ID Systems is a Symbol Business Partner, Zebra Premier Partner, Intermec Honors Partner and Microscan Preferred Partner. Our core offering includes wireless solutions, bar code printing & scanning systems, compliance labeling, warehouse and inventory management, print & apply systems, ERP interfaces, software solutions and media.

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Press Releases
• BarCode ID Systems Certified as Zebra Authorized XML Printer Specialist
• BarCode ID Systems Recertified as Zebra® Authorized Service Provider, Full Service
• Automotive Compliance Labeling System for GM Suppliers
• Supply Chain Execution Application for GM 1724 Labeling Standard
• AIM North America Elects Three New Directors

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