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BAR CODE SECRETS
Coupled with computer databases
and decoding logic, bar code labels can be made to serve as complex information carriers.
By now, most of us know that bar codes are used
for fast, super-accurate identification of product, or for error-free scanning of data
into a computer. Furthermore, by using completely automatic laser scanners, product
movement can be tracked, as cartons or pallets move from place to place.
The many possibilities for the best use of this
fast, accurate and sophisticated technology are not always so obvious. Let’s explore
some of its problem solving capabilities.
Bar code aliases
Problem: Bar codes are too long.
Solution: Use a 2 to 4 character
"alias" instead of the full length code.
A 2 character alpha-numeric code has 1156
different combinations (excluding L and O.) 3 characters have 39,304 combinations. An
additional "check" character gives only a 3% chance that an incorrectly keyed
value is accepted.
Advantages of encoding:
Easy to correctly key enter.
Easy to find the label ID visually
when searching for a pallet.
Easy to remember.
Bar code prints fast with little
ribbon wear.
Easy to scan as it is less
angle-dependent than a long label.
Takes up less room – you can
use a smaller label.
Multiple format bar codes
Problem:
Different items require different
categories of information in the bar code.
Solution: Use a variety of bar code formats
to satisfy the different needs.
Examples:
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Company ID and Part number –
IBMX1234567 (company=IBM, Part #1234567.)
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Part number and quantity –
1234567X1234 (Part #1234567, quantity=1234.)
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Part number and serial number
– 1234567X123456789 (Part #1234567, serial# =123456789.)
Requirements:
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Alpha-numeric code such as 3 of 9.
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Variable length format permitted.
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Custom decoder software – this
then is how each of the above formats would be decoded and sent to PC:
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IBM,1234567
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1234567,1234
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1234567,123456789
Reusable bar-codes for ID
Problem: How to identify an order
automatically?
Solution:
Use a reusable, short bar code.
Examples:
Bar coded totes divert only to
zones with picks, bypassing others.
Wooden "slave" pallet has
the bar code permanently attached.
Reusable clip-on bar code tabs for
cartons.
Implementation: Initial bar code
scan station to associate code with order number. May use OCR, document print sequence, or
document bar code.
Advantages:
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Large, easy to read bar codes and
man-readable letters.
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Low cost because they are reused
– very permanent.
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Uses inexpensive scanner
technology.
Build in redundancy
Problem: Murphy’s Law applies –
even with bar codes!
Solution: Build in the ability to
double-check everything (even if you rarely use it.)
Examples:
Verify product# to slot#.
Verify order# to group of part
numbers in order.
Verify calculated weight
Reuse emptied slots immediately for
received product, to verify the slot was really emptied.
Replenish to fill slot. This
insures you put product in correct slot. Also bar code verify with slot or product label
on slot.
Use a portable bar code terminal
for slot directed cycle counts. This is much faster than product directed cycle counts.
INTELLIGENT SHIPPING LABEL
Note below, how much information is encoded
into a relatively small bar code by use of multiple fields, encoding of data (carton
number), and use of a computer lookup table (order information.)
Graphic of intelligent shipping label
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If you don't find what
you need,
Ask Art
aavery@att.net 800-606-9841
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Some Recent Testimonials
(Contact us to speak
directly to a writer.)
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"Hi Art,
you are very welcome for the references. You may not know
this but we RAVE about the suggestions you made to us for
our "Distribution Center", and how right your
suggestions were…" Dan G.,
Pres., Pipersville, PA.
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"I look
forward to having you involved for our DC implementation plan
and in future endeavors as well. Your input was extremely
valuable to us".
Brent T., President Jacksonville, FL
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"This move
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Owner, Chicago, IL.
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"First
I wanted to say that all your suggestions work great! Thanks so much.
Secondly, in the later part of May, we will be moving out of our current
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you draw up a design. You told me if there were ever changes, just ask for
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"I
know it has been a while, but we finally signed on a new
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"We've
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