Toyoda Gosei reduce labelling errors to vanishing point

IT mamager uses Dolphin portable computers and ERP system to slash defect rating by over 99%

Toyoda Gosei Fluid Systems supply fuel pipes and aiir brake lines.to car manufactures.

Customers include Land Rover, Daimler Chrysler, Ford and Toyota.

Labelling and storage location errors
Differences between parts are slight, and it is incredibly difficult to tell them apart as they come out of a production cell.

Parts labelling and storage errors were too high and could have made the difference between keeping and losing customers.

Positive identication and ERP integration
IT Manager, Henry Nichols, was aiming for a drastic cut in errors from a few per thousand to a few per million.

Henry asked Codeway to help with a barcode tracking system to work with their new Fourman ERP system from XKO.

The wireless Dolphin 7200 hand held computers Codeway supplied contributed to a dramatic 99% plus decrease in labelling errors.

Barcode tracking system
The cells applied barcode labels identifying the product and their planned storage location.

This allowed the warehousemen to check every part was going into the right slot, simply by scanning two barcodes, one on the part and one at the storage location.

As the ERP now knew the exact location of every part, deliveries approached 100%.accuracy.

2D coding and total elimination of errors
When the Dolphin 7200s were due for replacement, Henry looked ahead to direct part marking and total eradication of labelling errors, He asked Codeway to recommend portable data terminals to scan 2D codes.

The Dolphin 9500 was an ideal match to the requirement, producing further improvements in accuracy and productivity.

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