Real-time WIP Shelf life Tracking with Barcode Technology for Defects Reduction
Article Sidebar
Main Article Content
Abstract
In manufacturing systems, the short shelf life of WIP (Work-in-process), categorized as a fast-moving product, can be a source of potential defects. PT XYZ is a cocoa industry located in Bandung. Manual labeling of product information in the wafer production line at PT XYZ failed to meet secure tracking and tracing requirements, resulting in increased defects due to inaccuracies in monitoring and quality control. To solve this problem, the author used the Gemba Kaizen approach as a tool companies use for continuous improvement achieved through small, low-cost steps. Our main idea is to introduce a new approach that utilizes alternative technologies by developing real-time applications to track WIP movement information in production. This barcode technology uses low-cost technology and has proven effective in helping production supervisors speed up decision-making of WIP management and minimize the risk of process failure in production that causes an increase in the number of defects. The results showed that the real-time system can reduce the number of defects from 2.6% to 1.6%. This can optimize overall inventory management and provide valuable insights for manufacturing companies looking to improve their operational efficiency through low-cost technology and real-time monitoring.
Article Details
This work is licensed under a Creative Commons Attribution 4.0 International License.
How to Cite
References
M. G. Khan, N. Ul Huda, and U. K. Uz Zaman, ‘Smart Warehouse Management System: Architecture, Real-Time Implementation and Prototype Design’, Machines, vol. 10, no. 2, Feb. 2022, https://doi.org/10.3390/machines10020150.
M. Khan, A. N. Alshahrani, and J. Jacquemod, ‘Digital Platforms and Supply Chain Traceability for Robust Information and Effective Inventory Management: The Mediating Role of Transparency’, Logistics, vol. 7, no. 2, Jun. 2023, https://doi.org/10.3390/logistics7020025.
N. N. de la Cruz and H. Daduna, ‘Analysis of second order properties of production–inventory systems with lost sales’, Ann Oper Res, vol. 331, no. 2, pp. 899–921, Dec. 2023, https://doi.org/10.1007/s10479-022-05061-z.
F. Al Barrak, Y. Al Meriouh, and M. Zniber El Mouhabbis, ‘Work In Process stock integrity in the automotive industry’, Prod Manuf Res, vol. 5, no. 1, pp. 2–14, Jan. 2017, https://doi.org/10.1080/21693277.2017.1322543.
X. Zhu, H. Shi, and Z. Jiang, ‘Linking Inventory Component Stickiness to Credit Ratings: The Moderating Role of Environmental Dynamism and Complexity’, Engineering Economics, vol. 34, no. 3, pp. 308–322, Jun. 2023, https://doi.org/10.5755/j01.ee.34.3.32735.
N. H. Z. Leung, A. Chen, P. Yadav, and J. Gallien, ‘The impact of inventory management on stock-outs of essential drugs in sub-Saharan Africa: Secondary analysis of a field experiment in Zambia’, PLoS One, vol. 11, no. 5, May 2016, https://doi.org/10.1371/journal.pone.0156026.
A. S. Mahapatra, H. N. Soni, M. S. Mahapatra, B. Sarkar, and S. Majumder, ‘A continuous review production-inventory system with a variable preparation time in a fuzzy random environment’, Mathematics, vol. 9, no. 7, Apr. 2021, https://doi.org/10.3390/math9070747.
S. Manuel, O. Vieira, and R. B. Lopes, ‘Improving production systems with lean: a case study in a medium-sized manufacturer’, International Journal of Industrial and Systems Engineering, vol. 33, no. 2, 2019, https://doi.org/10.1504/IJISE.2019.102469.
S. G. Gebeyehu, M. Abebe, and A. Gochel, ‘Production lead time improvement through lean manufacturing’, Cogent Eng, vol. 9, no. 1, 2022, https://doi.org/10.1080/23311916.2022.2034255.
F. Paschko, S. Knorn, A. Krini, and M. Kemke, ‘Material flow control in Remanufacturing Systems with random failures and variable processing times’, Journal of Remanufacturing, vol. 13, no. 2, pp. 161–185, Jul. 2023, https://doi.org/10.1007/s13243-023-00126-z.
M. Bimpizas-Pinis, R. Santagata, S. Kaiser, Y. Liu, and Y. Lyu, ‘Additives in the food supply chain: Environmental assessment and circular economy implications’, Environmental and Sustainability Indicators, vol. 14, Jun. 2022, https://doi.org/10.1016/j.indic.2022.100172.
C. Cevoli, A. Evangelisti, P. Gradari, and A. Fabbri, ‘Storage of wafer cookies: Assessment by destructive techniques, and non-destructive spectral detection methods’, J Food Eng, vol. 336, p. 111209, Jan. 2023, https://doi.org/10.1016/j.jfoodeng.2022.111209.
T. Fadiji, M. Rashvand, M. O. Daramola, and S. A. Iwarere, ‘A Review on Antimicrobial Packaging for Extending the Shelf Life of Food’, Processes, vol. 11, no. 2. MDPI, Feb. 01, 2023. https://doi.org/10.3390/pr11020590.
B. Mandal, B. K. Dey, S. Khanra, and B. Sarkar, ‘Advance sustainable inventory management through advertisement and trade-credit policy’, RAIRO - Operations Research, vol. 55, pp. 261–284, Jan. 2021, https://doi.org/10.1051/ro/2020067.
A. Simegnaw Ahmmed and M. Ayele, ‘In-Depth Analysis and Defect Reduction for Ethiopian Cotton Spinning Industry Based on TQM Approach’, Journal of Engineering (United Kingdom), vol. 2020, 2020, https://doi.org/10.1155/2020/5792434.
W. Zhou and S. Piramuthu, ‘Effects of ticket-switching on inventory management: Actual vs. information system-based data’, Decis Support Syst, vol. 77, pp. 31–40, Jun. 2015, https://doi.org/10.1016/j.dss.2015.05.010.
J. C. Quiroz-Flores and M. L. Vega-Alvites, ‘Review Lean Manufacturing Model of Production Management Under the Preventive Maintenance Approach to Improve Efficiency in Plastics Industry Smes: A Case Study’, South African Journal of Industrial Engineering, vol. 33, no. 2, pp. 143–156, 2022, https://doi.org/10.7166/33-2-2711.
R. Rathi, M. C. G. Reddy, A. L. Narayana, U. L. Narayana, and M. S. Rahman, ‘Investigation and implementation of 8D methodology in a manufacturing system’, in Materials Today: Proceedings, Elsevier Ltd, 2021, pp. 743–750. https://doi.org/10.1016/j.matpr.2021.05.273.
O. Benmoussa, ‘Improving Replenishment Flows Using Simulation Results: A Case Study’, Logistics, vol. 6, no. 2, Jun. 2022, https://doi.org/10.3390/logistics6020034.
S. Islam, L. Manning, and J. M. Cullen, ‘Systematic assessment of food traceability information loss: A case study of the Bangladesh export shrimp supply chain’, Food Control, vol. 142, Dec. 2022, https://doi.org/10.1016/j.foodcont.2022.109257.
T. K. Agrawal, L. Koehl, and C. Campagne, ‘A secured tag for implementation of traceability in textile and clothing supply chain’, International Journal of Advanced Manufacturing Technology, vol. 99, no. 9–12, pp. 2563–2577, Dec. 2018, https://doi.org/10.1007/s00170-018-2638-x.
M. Folwarczny, V. Sigurdsson, R. G. V. Menon, and T. Otterbring, ‘Consumer susceptibility to front-of-package (FOP) food labeling: Scale development and validation’, Appetite, vol. 192, Jan. 2024, https://doi.org/10.1016/j.appet.2023.107097.
J. Isohanni, ‘Use of Functional Ink in a Smart Tag for Fast-Moving Consumer Goods Industry’, J Packag Technol Res, vol. 6, no. 3, pp. 187–198, Oct. 2022, https://doi.org/10.1007/s41783-022-00137-4.
G. N. Hlongwane, D. Dodoo-Arhin, D. Wamwangi, M. O. Daramola, K. Moothi, and S. E. Iyuke, ‘DNA hybridisation sensors for product authentication and tracing: State of the art and challenges’, South African Journal of Chemical Engineering, vol. 27. Elsevier B.V., pp. 16–34, Jan. 01, 2019. https://doi.org/10.1016/j.sajce.2018.11.002.
T. Sriram, K. Vishwanatha Rao, S. Biswas and B. Ahmed, ‘Applications of barcode technology in automated storage and retrieval systems,’ Proceedings of the 1996 IEEE IECON. 22nd International Conference on Industrial Electronics, Control, and Instrumentation, Taipei, Taiwan, 1996, pp. 641-646 vol.1, https://doi.org/10.1109/IECON.1996.571035.
J. Ning and S. Yu, ‘Barcode Location in Financial Statement System Based on the Partial Differential Equation Image Recognition Algorithm’, Advances in Mathematical Physics, vol. 2021, 2021, https://doi.org/10.1155/2021/9177159.
Y. Wu, D. R. Lougheed, S. C. Lougheed, K. Moniz, V. K. Walker, and R. I. Colautti, ‘baRcodeR: An open-source R package for sample labelling’, Methods Ecol Evol, vol. 11, no. 8, pp. 980–985, Aug. 2020, https://doi.org/10.1111/2041-210X.13405.
A. J. Copp, T. A. Kennedy, and J. D. Muehlbauer, ‘Barcodes Are a Useful Tool for Labeling and Tracking Ecological Samples’, The Bulletin of the Ecological Society of America, vol. 95, no. 3, pp. 293–300, Jul. 2014, https://doi.org/10.1890/0012-9623-95.3.293.
T. M. Fernández-Caramés, O. Blanco-Novoa, I. Froiz-Míguez, and P. Fraga-Lamas, ‘Towards an Autonomous Industry 4.0 Warehouse: A UAV and Blockchain-Based System for Inventory and Traceability Applications in Big Data-Driven Supply Chain Management’, Sensors (Basel), vol. 19, no. 10, May 2019, https://doi.org/10.3390/s19102394.
S. Kumar, A. Dhingra, and B. Singh, ‘Lean-Kaizen implementation’, Journal of Engineering, Design and Technology, vol. 16, no. 1, pp. 143–160, Feb. 2018, https://doi.org/10.1108/JEDT-08-2017-0083.
A. Androniceanu, I. C. Enache, E. N. Valter, and F. F. Raduica, ‘Increasing Energy Efficiency Based on the Kaizen Approach’, Energies (Basel), vol. 16, no. 4, Feb. 2023, https://doi.org/10.3390/en16041930.
H. Kozhabayev, G. Mombekova, B. Keneshbayev, and S. Yessimzhanova, ‘Possibilities of Applying the Kaizen System for Improving Quality Management in the Context of ESG Development’, Quality - Access to Success, vol. 24, no. 197, pp. 24–34, Oct. 2023, https://doi.org/10.47750/QAS/24.197.04.
R. Y. Romansyah, H. Azis Budiarto, Y. Yasin Erlangga, and Y. N. Safrudin, ‘Failure Investigation Of Blank Holder Force (BHF) Control In The Outside Bracket for Front Seat’, JAETS, vol. 4, no. 2, pp. 756–764, 2023, https://doi.org/10.37385/jaets.v4i2.1779.
A. Cherrafi et al., ‘Green and lean: a Gemba–Kaizen model for sustainability enhancement’, Production Planning and Control, vol. 30, no. 5–6, pp. 385–399, Apr. 2019, https://doi.org/10.1080/09537287.2018.1501808.
J. L. García-Alcaraz, A. S. Morales García, J. R. Díaz-Reza, E. Jiménez Macías, C. Javierre Lardies, and J. Blanco Fernández, ‘Effect of lean manufacturing tools on sustainability: the case of Mexican maquiladoras’, Environmental Science and Pollution Research, vol. 29, no. 26, pp. 39622–39637, Jun. 2022, https://doi.org/10.1007/s11356-022-18978-6.
J. A. Garza-Reyes et al., ‘Deploying Kaizen events in the manufacturing industry: an investigation into managerial factors’, Production Planning and Control, vol. 33, no. 5, pp. 427–449, 2022, https://doi.org/10.1080/09537287.2020.1824282.
Pradana, T. Djatna, I. Hermadi, and I. Yuliasih, ‘Blockchain-based Traceability System for Indonesian Coffee Digital Business Ecosystem’, International Journal of Engineering, Transactions B: Applications, vol. 36, no. 5, pp. 879–893, May 2023, https://doi.org/10.5829/ije.2023.36.05b.05.
M. L. Tseng, S. X. Li, M. K. Lim, T. D. Bui, M. R. Yuliyanto, and M. Iranmanesh, ‘Causality of circular supply chain management in small and medium-sized enterprises using qualitative information: a waste management practices approach in Indonesia’, Ann Oper Res, 2023, https://doi.org/10.1007/s10479-023-05392-5.
R. K. Wassan, Z. H. Hulio, M. A. Gopang, U. Sarwar, A. Akbar, and S. Kaka, ‘Practical Application of Six Sigma Methodology to Reduce Defects in A Pakistani Manufacturing Company’, Journal of Applied Engineering Science, vol. 20, no. 2, pp. 552–561, 2022, https://doi.org/10.5937/jaes0-34558.
H. Zhang et al., ‘Integrated food quality monitoring QR code labels with simultaneous temperature and freshness sensing in real-time’, Journal of Food Measurement and Characterization, vol. 17, no. 5. Springer, pp. 4834–4842, Oct. 01, 2023. https://doi.org/10.1007/s11694-023-02007-2.
M. A. M. Shukran, M. S. Ishak, and M. N. Abdullah, ‘Enhancing Chemical Inventory Management in Laboratory through a Mobile-Based QR Code Tag’, in IOP Conference Series: Materials Science and Engineering, Institute of Physics Publishing, Aug. 2017. https://doi.org/10.1088/1757-899X/226/1/012093.
G. Fragapane, R. Eleftheriadis, D. Powell, and J. Antony, ‘A global survey on the current state of practice in Zero Defect Manufacturing and its impact on production performance’, Comput Ind, vol. 148, Jun. 2023, https://doi.org/10.1016/j.compind.2023.103879.
S. Pagliusi et al., ‘Vaccine traceability: Key learnings from the supply chain initiative by manufacturers from emerging countries’, Vaccine X, vol. 15, Dec. 2023, https://doi.org/10.1016/j.jvacx.2023.100366.
K. Küng et al., ‘Effect of barcode technology on medication preparation safety: A quasi-experimental study’, International Journal for Quality in Health Care, vol. 33, no. 1, 2021, https://doi.org/10.1093/intqhc/mzab043.
R. Chen et al., ‘Rewritable and sustainable 2D barcode for traceability application in smart IoT based fault-tolerant mechanism’, Sustainability (Switzerland), vol. 12, no. 17, Sep. 2020, https://doi.org/10.3390/su12177192.
K. Naji, S. Gowid, and S. Ghani, ‘AI and IoT-based concrete column base cover localization and degradation detection algorithm using deep learning techniques’, Ain Shams Engineering Journal, vol. 14, no. 11, Nov. 2023, https://doi.org/10.1016/j.asej.2023.102520.
H. A. Arjes et al., ‘Construction and characterization of a genome-scale ordered mutant collection of Bacteroides thetaiotaomicron’, BMC Biol, vol. 20, no. 1, Dec. 2022, https://doi.org/10.1186/s12915-022-01481-2.
D. M. Segura Velandia, N. Kaur, W. G. Whittow, P. P. Conway, and A. A. West, ‘Towards industrial internet of things: Crankshaft monitoring, traceability and tracking using RFID’, Robot Comput Integr Manuf, vol. 41, pp. 66–77, Oct. 2016, https://doi.org/10.1016/j.rcim.2016.02.004.
G. Yanhua, Z. Sihua, Z. Xiaodong, C. Bojun, and W. Shaohui, ‘Research on quick response code defect detection algorithm’, Cybernetics and Information Technologies, vol. 17, no. 1, pp. 135–145, 2017, https://doi.org/10.1515/cait-2017-0011.
F. Siaw-Yeboah, --- Mark, A. Boateng, and ---Alex Kwaku Peprah, ‘Digitizing Processed Food and Medicinal Products for Consumers’ Safety in Ghana, Using Barcode Technologies’, International Journal of Creative Research Thoughts, vol. 8, no. 4, pp. 1971–1985, 2020.