Case #1 — CD Fulfillment
The Problem:
Mail order CD shipper needed to double capacity on its labeling line, reusing existing equipment.

The Components:
• Database lookup
• Label format lookup
• Alternating print and apply units
• Accommodates line stops
• Label-to-Order verification
• Automatic kicker interface
• Network printer control
• Automated and manual systems
• Running for 2 years non-stop

The System:
• Operator selects label format to use
• Invoice is scanned by fixed mount scanner
• Shipping label is printed and applied
• Invoice and label are scanned and compared, mismatches are diverted

All original equipment was reused and a second print & apply system was added to the original line with labels being alternately sent to each machine, maintaining queue and application timing during frequent line starts and stops.

Due to past difficulties with labeling software vendor and difficulties in working with them to improve the system, the scope of the application grew from doubling one line to replacing the labeling system on 3 lines and 8 manual workstations with a centrally managed system.

Case #2 — Automotive Compliance
The Problem:
Company incurring large fines and risking losing a customer due to incorrectly labeling products.

The Components:
• Compliance labeling
• PLC (Programmable Logic Controller) interface
• Central control of label formats
• Variable formats, based on inputs
• Variable quantity, based on forma
• Automatic pass/fail labels

The System:
• Integration of a labeling system with PLCs to automatically print the correct item labels and case labels
• PLC sends control signals to identify item and whether or not it passed the test
• Signals interpreted, then appropriate label is retrieved from the network
• Label fields filled automatically with appropriate data from signals
• Label printed
• System keeps track of item labels printed, then prints the case label at the appropriate time (multiple items included in a single case; case label only printed when case is full)
• Solution implemented on multiple lines with multiple printers on each line, giving control of compliance mandates and label format management to customer

BarCode ID Systems has been re-engaged to provide two enhancements to the original system, installed in 2008, in order to increase the functionality of the system due to changing business requirements.

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Case #3 — Book Distribution Center Packing & Sorting Systems
The Problem:
Conversion of manual product packing and sorting operation to fully-automated system.

The Components:
• Weight check
• Automatic sorting to packing lines
• Automatic shipping label application
• Shipping label-to-case verification
• Automatic sort to dock door
• PLC interface
• User configurable sorting
• Trailer manifesting
• Data push to UPS
• High-speed system (70 packages per minute)
• Running for 5+ years non-stop

The System:
• Stack of books is manually placed online, then not touched again until final shipping box is stacked on truck
• Stack is weight checked...
-sorted to be packed in right size box...
-packed, sealed, and labeled with shipping/contents labels...
-verified for correct label-to-case match...
-sorted to one of four shipping lines...
-manifested to UPS
• Managers are notified via email/SMS for any critical errors
• Scales, fixed-mount scanners, databases, ink jet printers, PLCs, print & apply units, automatic diverters, FTP, and email are used throughout the system

BarCode ID Systems has been re-engaged to provide six enhancements since the original install over five years ago, to refine existing functionality and accommodate changing business requirements.

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