This will probably be the last barcode-related blog entry for a while. I wanted to share another interesting solution for handling a busy tool crib using wireless barcode scanning technology.
The problem is probably a common one: how to efficiently distribute tools (or parts) while still maintaining usage and accountability. In this case, the tool crib was always attended but could be quite slow at times while the attendant searched and gathered tools. It would be like waiting in line at the store while the cashier continuously called the manager for price checks. You can image how quickly the workers would get frustrated.
At the facilities of one MAPCON CMMS Software customer, there were two parts of the solution that drastically helped reduced the long wait times. The first part was a well thought out Kardex carousel system, which is a different topic entirely. The second part was implementing a wireless barcode system to go with it.
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I am an experienced trainer for Computerized Maintenance Management System (CMMS) software. As most of you know, for the most part, CMMS entails use of preventative maintenance software deployed in industrial installations such as manufacturing operations, or, facilities such as hospitals and schools to monitor and protect physical assets and capital equipment. This CMMS software is critical to preserving productivity as well as lowering operating costs by preventing equipment failure and unscheduled ‘downtime’.
In my profession, a major consideration is not just the introduction of the CMMS concept, but the question of training a diverse user group at innumerable plants and facilities on how a specific preventative maintenance software package works for their unique operation. And, the answer is always a cagey, “It depends!”
Management is not likely (nor should they) spend an inordinate amount of money on CMMS training classes specifically ‘customized’ for the needs and expectations of such varied job classifications as, ‘planner’, ‘draftsperson’, ‘plant manager’ or ‘safety director’. Yet, each individual looks at their particular operational process through a different lens. Each has different responsibilities within the organization so daily work experiences vary widely. One thing though that seems to help the trainer is to remember the rule used in public speaking, “Know your Audience”.
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No storeroom attendant? Use barcoding to keep track of inventory and reordering!
While writing about barcode topics in recent articles, I recall some interesting solutions I’ve encountered over the years. One that comes to mind was a fairly simple remedy to the age-old question: How to monitor items leaving and returning to the storeroom without a storeroom attendant?
Obviously, no system is perfect. For instance, an RFID chip (radio frequency identifier chip) similar to those used to prevent shoplifting can silently detect an item as a person leaves the storeroom and automatically update inventory. Yet, even an RFID chip solution has its flaws. I can remove the RFID tag. Regardless, we need something simple so that during an emergency rush, the worker can pull the parts, scan them and go without a lot of frustration and waiting.
One simple solution given these circumstances was a company that printed barcoded labels, affixed them to 3×5 index cards and placed a stack of them at each bin location. When it came time to use a part, the worker simply took what they needed and took a card for each item. On the way out the door, the worker scanned their badge, scanned the cards and then discarded the 3×5 inventory cards. The work order management software system did the rest.
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And your maintenance staff: protecting your most valuable assets
Ask any CEO what he considers to be his most valuable assets, and more often than not the reply will be, “My people”. Successful companies realize the investment they have in their employees and credit them for the contributions they make daily to insure the continued growth of the business.
As well, great companies take necessary steps to keep their workforce updated in skills necessary to compete in today’s marketplace. Training seminars in the latest Safety, Production or Maintenance practices, or on-the-job Cross-Training all contribute to the overall education and productivity of their employees.
The focus of this article is on the value to the organization of a good Computerized Maintenance Management Systems (CMMS) and, the company’s “most valuable of the most valuable”, the Maintenance Staff.
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This article is the next installment in the Series about MAPCON Facility Maintenance Software written by Joni Brown, Embry-Riddle Aeronautical University Facility Management. Please see her previous Article: The Genesis of Preventative Maintenance Software.
Last time we met, I wrote about Embry-Riddle Aeronautical University’s progression in computer technology from the 1980’s through later times, specifically our experience using Preventive Maintenance or Facility Maintenance Software. One of the Facility Maintenance Software packages we considered was developed by the software engineers at MAPCON Technologies, Inc.
As we worked through the features offered by MAPCON and the other package that had survived our intense scrutiny, there was ONE thing missing, and it was a deal breaker.
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Keeping with the barcoding theme, I thought I’d share some ideas on how to use all those labels you printed. Obviously, you can affix labels to part bins. But what about those odd assortments that aren’t in bins, or maybe those parts still in boxes or sitting on pallets? Well, here are some ideas:
Some users of CMMS Software keep stockroom inventory parts in Ziploc bags, then affix a barcode label to the Ziploc bag. This can be helpful if a bin contains a collection of parts and you want to only issue out so many at a time, (such as 4 1” hex bolts).
By the way, it’s a good idea to use Ziploc bags to protect an item from dust or other contaminants.
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How reactive are you? For instance, if you knew you would never have another unplanned breakdown, would you even need a stockroom at all? Of course, this is unrealistic and not likely to ever happen – but how far do you go the other direction? The more reactive you become, the bigger the stockroom you need – with more parts available on a moment’s notice.
The idea behind using MAPCON Equipment Maintenance Software is to help take control of your maintenance program, and not just wait for something to happen and then react. If you know the condition of the equipment and follow your PM procedures on a regular basis, break downs and emergency repairs should disappear over time.
At the very least, costly unplanned repairs are greatly reduced, and the items needed to perform repair work will shrink the overall stockroom size necessary for getting the job done. And, that’s the point! The objective is to lower costs by prudently reducing your stockroom inventory.
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Most of the time, people want to know why they should go through the effort of barcoding each and every Inventory item they have. In some cases, for instance for smaller shops, it may not be worth the effort. However, for larger storerooms, say 1000 parts or more, it can help reduce data maintenance software entry errors and improve performance when issuing or counting parts.
Think about it, a scanner takes less than a second to enter the number for issuing or counting. That’s a lot less time than it takes anyone to search for an item and enter it in by hand.
Regardless, most barcode startup questions revolve around how to make a barcoded label, what should be on the label, where to put the labels, how to print the labels, and so on.
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