Over the years we have developed several weighing systems for various clients in the cosmetics field. The problems that need to be addressed are common to all, but the real pitfall is often the result of custom, customer-requested programs that are often found to be botched due to lack of prior analysis or underestimation of issues.
Often, such snags come from both the company and the developer being lacking in experience in this area. The weighing process is a fundamental activity that ensures a production flow according to standards that every cosmetic company is forced to manage judiciously. The inclusion of real-time detection software in this area can either be a competitive advantage (if developed appropriately) or a ballast to contend with on a daily basis.
Why customized programs?
The demand for customized programs as opposed to standard programs, although the result is common (and we will see what you want to achieve next), depends on customers who want to optimize weighing times based on the methodology applied over the years and used by their operators, without upsetting their work habits too much. Like any good IT customization, the weighing module, too, must adapt to the user without distorting its nature. Standard software will still need to be customized, and optimization work will still be necessary.
Common flow
As mentioned earlier, the flow-that is, the problems and how to solve them-is really common and is summarized in the diagram opposite.
The flow is divided into timeframes (highlighted by the vertical blocks) and the two horizontal bars representing the application scope (ERP Software and Weighing Module) and shows the actions performed for proper information management.
Stage 1
Like any production, the initial startup is triggered when a product order line is entered. The order can be of various types:
- Finished product orders from customer
- Bulk order from customer
- Internal order order for warehouse re-integration
In each case this will have to say what we need to produce, how much we need to produce, and possibly the date by which to produce.
Stage 2
This activity is divided into two parts: the first, fully automatic while the second is semi-automatic.
Step 2.1
The weighing module, by reading and synchronizing order rows with the company ERP (integration can be done in multiple modes), will transpose changes and new productions with all necessary data.
This whole phase is an automatic procedure that can be launched independently by the system by running it at predefined time intervals.
Step 2.2
Based on the synchronization we will have to plan the production dividing the work order into its processing charges. This is a special feature of the industry that we will address in a later post. The choice may be of two types:
- Fully manual: the operator will choose how and how much to divide
- Semi-automatic: the system will propose values based on configuration parameters
The result of phase 2 will be to generate a weighing plan for the various locations by dividing, through the structure of the configured BOMs, the components to be weighed. The components may be either raw materials or semi-finished products.
The phase may be performed several times in the day according to business needs.
Stage 3
Upon confirmation of step 2, the weighing module will alert the manager who will view the weighing plan (the ODLs divided into charges) according to the priority criterion established by the company. This control station may be directly a terminal in weighing or a dedicated page on the manager's station. Always consider extrapolating the lists that a software provides in excel format because it is very convenient to process out of the system or to use as paper summaries.
Stage 4
The weighing station could have several hardware features. First, it could be a touch-screen station with a barcode reader; alternatively, it could be a handheld device with an integrated barcode reader. Of these devices there are many brands. Among the most popular are Motorola, Denso, and Zebra. Optionally, but highly recommended, integration of the signal from the scales so that the measured data (the weight) is directly handled by the system and not manually imputed by the operator. Integration of scales can be done in various ways, which we will see in a future article.
What should a weighing module display?
The information to be displayed is multiple and will require the use of multiple masks. The minimum list to be requested is as follows:
- ODL list to be weighed: this mask is useful if a completely paperless system is desired. As an alternative to this one could use a barcode on the ODL and, upon reading this, take the operator to the next mask.
- Component list: the second mask, once ODL/load to be weighed has been chosen, will display all components (in table format) with the quantities to be weighed and weighed. In this mask we will choose the component (via touchscreen or barcode) and the system will prepare for weighing.
- Available lot list: having to manage component lots it will be useful, once the material to be weighed has been chosen, to have a list of lots (sorted by FIFO, LIFO, FEFO, etc.) with possible locations. In this way, only valid lots will be accepted giving feedback to the operator if they make a mistake in picking (via barcode reading)
Tips for the graphical user interface
Always remember to keep the masks simple with very large, easy-to-read fonts (this is not a program used in the office but in production). Information should be visually punchy (pictures, colors, etc.) and any error signals should attract the operator's attention.
Label and weighted uniqueness
With each weighing, the system will have to print unique labels containing important information for material traceability and to ensure weighing uniqueness. Each weighing will have to be managed in the weighing module database by attaching automatic information such as:
- ODL and charge
- Weighing code (usually an autogenerated sequence number)
- Part number
- Component lot
- Quantity required
- Weighed quantity
- Weighing operator
- Date/time/minutes and seconds of weighing
These 8 data constitute the unique identification of the weighing within the entire weighing system.
Container baskets
We have always recommended that the first time an ODL/load is weighed, a label containing the basic data of the ODL to which it belongs should be printed. Such a label will thus create a virtual warehouse of the various weighed components so as to group them together and not scatter bags mistakenly to other productions. To do this you will have to allocate adequate space for both weighing and production so that the baskets can be conveniently and safely transferred. Label reading by terminal will allow the operator to know the contents of the basket at all times.
Step 5
Step 5 may change according to the needs and features of the enterprise ERP software. The simplest case is to create a stock movement (stock transfer) at each weighing for the quantity/component/batch. You will automate this transfer from the RAW MATERIALS/STOCK warehouse to the WEIGHTS WAREHOUSE.
Alternatively, instead of creating each movement at the same time as each weighing, you can create a mask within the weighing module that will list all the weighings executed and not yet "moved" in the ERP and manually launch the execution of the movement. The two solutions are still valid but have pros and cons, respectively. One tip is to have a weighing module that allows you to choose the two modes of action via configuration parameters so that you can decide at any time whether to use the automatic type or not.
Automatic transfers vs. manual transfers
Automatic transfers
- Pro 1: stock updated in real time
- Pro 2: Queries for lot availability are easy because everything is in real time
- Cons 1: If the operator makes a mistake in weighing you must have a routine available that reverses the stock transfer. Usually this procedure is very complex
Manual transfers
- Pro 1: Any weighing can be checked and possibly changed by hand
- Cons 1: More complex batch inventory queries (must account for products weighed and not yet transferred)
- Cons 2: Need for an operator to act as a super-vision.
Both choices are valid, so it is just a matter of being able to field test what is best for your company. That is why we recommend a system that has both choices and gives you wide margins for parameterization.
Step 6
The last phase under consideration is not so much about the weighing module but more about starting the second production phase proper. Basically, with the components weighed and identified in their own bags/baskets, we have the ability (only if we go through weighing software first) to be able to directly download through the use of barcodes the components during bulk production.
This flow is not analyzed in this post but we will describe it in a later one.
Conclusions
The weighing module is one of the essential modules for digitizing your business. Using it ensures:
- Effectiveness
- Accuracy
- Creating data for future analysis
- Traceability and traceability
- Error correction and real-time reporting
The module is part of a series of available software that ensures fast and fully digitized operational flows. If you are interested in learning more about all the software download from the following link our operating manual dedicated to the cosmetics industry for building a complete and functional information system. In the document we will analyze all the necessary and essential software for a cosmetic company and how to integrate them with each other.
If you would like to schedule an appointment with one of our technicians, contact us by pressing this LINK. We can talk in person about all the problems we have faced and solved in our years of working with companies in the cosmetics industry. A digitized company is an efficient and competitive company and is the only way to win in today's market.
