How to Guarantee Packaging Compliance (Part 4 of 4)

Our conclusion to this series focuses on the final two requirements for achieving packaging compliance. Visit our previous installments by clicking on the links below:

Part 1: Levels of packaging, the unique characteristics of each and what information should be included on packaging

Part 2: The risks of non-compliance

Part 3: Understanding manufacturing and application requirements and levels of message validation

KEY CONSIDERATION 3: PACKAGING AUTOMATION & CONTROL

Proactive & Reactive Control of Packaging

Achieving guaranteed packaging compliance requires more than selecting the most optimal product coding technology and the right level of message validation for your operation. To ensure high quality real-time manufacturing codes are printed consistently, proactive material handling best practices need to be in place.

Proper material handling when working with coding equipment includes:

• Low vibration conveyors to reduce interference with the application of real-time print messages on the products
• Railing selections and configurations that consistently present the product to the coding technology for message application
• Tolerant product coding technology that provides consistent performance and enough flexibility to apply a quality code when there are slight inconsistencies in material handling

To guarantee packaging compliance, reactive measures also need to be worked into the overall material handling plan in order to separate noncompliant product from acceptable product. This prevents non-compliant products from ever reaching the customer. When material handling is used with scanner message validation, production lines can be shut down or, if there is enough space available in the production environment, out-of-spec packages can be automatically separated from the rest of the products if they are deemed unreadable or incorrect.

Reactive material handling measures often referred to as “reject systems” include:

• Jets of air
• Pusher arms
• Drop belts

Once a package has been deemed as illegible or non-compliant and an auto-reject measure takes place, manufacturers can choose to rework the code application or scrap the product altogether.

When choosing to rework the code application, the non-compliant code is either removed, redacted or left in place. Manufacturers either opt to send the product back through the product coding step on the normal production line or have a separate rework station set up to reapply the manufacturing codes.

Scrapping product due to illegible codes can be expensive. Manufacturers that choose this option understand the time and costs involved with rework and opt to scrap product when it is a more cost-effective option than going through a rework process. Tightly controlled message validation and material handling measures can help reduce the amount of product impacted by illegible codes. This keeps the amount of product that needs to be reworked or scrapped to a minimum.?

Programmable Corrective Measures

• Option 1: Full production line shutdown for corrections
• Option 2: Reject, redirect and rework
• Option 3: Reject, redirect and scrap

KEY CONSIDERATION 4: DATA MANAGEMENT

Achieving Automated Compliance Through Data Connectivity

Underperforming coding technology and poor material handling measures are not the only causes of packaging non-compliance. Manufacturers often find that user error is to blame for improper codes being applied to products. To minimize instances of user error in the print message creation and selection process, information can be drawn from a centralized database to auto-populate the print messages. This allows manufacturers to take basic message selection and editing responsibilities out of the hands of line workers and instead rely on automation to do the heavy lifting when it comes to variable print message editing and selection.

One-way Data Management

One-way data management leverages existing databases to populate components of print message formats that are required by regulators and retailers. Database linked messages are then sent in real-time to the printer for use.

• Centralized control point for variable message creation and management
• Seamless integration with company databases automates manual input of variable information
• Validated data matched to print messages protects against user error
• Less manpower required from IT and operations to create and maintain message formats

Two-way Data Management

Two-way data management enables manufacturers to get real-time feedback from in-line equipment to further drive operational insights.

• Equipment availability reporting allows for the monitoring of equipment status in real time as well as drives long-term up-time insights
• Message validation tracking helps to understand the print performance of coding technologies and overall compliance achieved
• Realtime production insights provides throughput analytics to measure uptime productivity

Managing the integration of data down to the production floor allows for manufacturers to seamlessly and efficiently ensure the right information is being printed on the right products – ultimately helping manufacturers achieve automated compliance.

INDUSTRY 4.0 AND PACKAGING COMPLIANCE 
Industry 4.0 allows data to be integrated from the office to the production floor, enabling manufacturers to seamlessly ensure the right information is being printed on the right products while remotely monitoring and managing the overall productivity of the equipment.        

CONCLUSION

It is possible to guarantee packaging compliance through automation. The chosen product coding technology, message validation process, material handling configuration and data management practices are all key to a successful game plan.

Speak with a Diagraph packaging compliance specialist today to better understand your compliance risks and build a custom game plan that is ideal for your production environment.

https://www.diagraph.com/