Case Study | Ichiban UK | C WRAP Label
Implementing Autocoding
to Comply with Retailer Code
of Practice
At a Glance
What they wanted to do
• Implement an automated
label and date code
verification system.
• Integrate the system into
current set-up including
printers.
• Support operational
efficiency and productivity.
What were the success criteria
• The system had to comply
with the retailer codes of
practice.
• The system had to integrate
with existing packaging line
devices.
• To not interrupt the 24/7
operation of the factory.
What they accomplished
• Compliance with retailer
codes of practice.
• Optimise their factory
productivity and efficiency.
• Ability to plan ahead
and proactively reduce
downtime.
Customer
Ichiban UK Ltd is the largest sushi manufacturer in the UK. They produce both own label and branded
authentic sushi for major retailers in a growing UK market. At their single site in Suffolk they employ over
450 staff in a 24/7 operation, last year alone they cooked around 1200 tonnes of rice.
Challenge
Ichiban UK contacted OAL to investigate the implementation of a label verification and date code control
system in response to the introduction of stricter rules, regulations and codes of practices set by retailers.
Breaches of these codes of practice can result in substantial fines as well as loss of reputation.
The increasing consumption and popularity of sushi meant any installation needed to minimise downtime
to maintain capacity. Ichiban UK hoped to use the installed system for both compliance and to drive
operational efficiency and productivity on the shop floor.
Julie Rice, Technical Manager explains why Ichiban UK chose OAL:
“We chose the OAL system because it’s a tried and tested solution that provides
the compliance we need. It’s easy to use and has helped us focus by accurately
recording line stoppages and identifying areas for improvement.”
Technical Solution
OAL Autocoding was installed across four packing
lines at Ichiban UK to ensure the correct label,
date code and price has been applied to products.
A touch screen terminal was installed on each
line that linked to scanners, C Wrap labellers, Ice
printers (Ice Thermal Transfer labeller), and Mettler
Toledo checkweighers with a master database
of products. A fifth mimic terminal was installed
in the Low Risk area for operators to carry out
routine quality checks and to scan outer case
label barcodes, ensuring products are packed in
the correct case. Three interesting features of the
system are:
2D Coding & Scanning
2D barcoding and scanning allows Ichiban UK to
scan products without using the EAN barcode
which means all areas of packaging are traceable
(to ensure the correct version of labels are used).
This simple system reads every single code that
passes through the scanner and compares it to the
job inputted within the system by the line operator.
If a mismatch error occurs, the line completely
stops removing the risks that ensure they meet
the retailer’s requirements and are fully compliant.
Unlike 1D barcodes, 2D barcodes provide complete
control over the version of packaging used. 2D
barcodes are not under the control of the retailer,
so can be adjusted when there are any minor
changes to the packaging to ensure that old
packaging is not used.
OEE Performance
If an incorrect label is on the line, the line stops
and a supervisor must investigate before the line
can restart. Operators must then record on the
touchscreen terminal the reason for the stop thus
collecting actionable data. The data is both highly
accurate and can be used in real-time so actions
can be taken if any issues occur. The automatic
system replaces existing manual production logs,
providing more accurate and reliable data.
Promo Labels
The OAL Autocoding system provides assurance
over the correct use of promo labels. By applying
a 2D code to the front of the label or printing a
2D code onto the backing paper, the label can be
scanned. If the product does not require a promo
label, the scanner will either detect the wrong
barcode or will detect a consecutive no read and
stop the line.
Results
The OAL Autocoding system has provided peace
of mind to Ichiban UK by securing the label,
date codes and price on their packaging. The
system was installed quickly with minimal factory
downtime.
Ichiban UK uses the system to identify and
improve production performance as the OAL
system automatically records downtime. The
accurate date is then used to proactively prevent
issues arising on the packaging line.
Olympus Automation trading as OAL
A1 Parkway, Orton Southgate, Peterborough,
Cambridgeshire, PE2 6YN, United Kingdom
Tel: +44 (0) 1733 394700 Fax: +44 (0) 1733 394901
Web: www.oalgroup.com
Email: [email protected]