Reducing Your Workload Through BARCODING
By Michelle Garetson
November 1998
Although automatic data capture (ADC), more specifically, barcoding, has been around for over thirty years; most aviation-related businesses still have not fully embraced this concept of implementing such technology into their operations to realize the benefits. Barcoding can be used for industry applications such as parts inventory and labor tracking, and has long proven to be a cost-effective solution for accurate data capture, eliminating the need for manual data entry.
Aviation's reluctance to use barcoding might be attributed to the lack of standardization for symbologies — the barcode configurations, within the industry. Those companies that were the innovators in the establishing a barcode system early on, developed their own standards for symbologies and required their suppliers to comply with those standards. Suppliers were then faced with having to have several standards of coding in place to service all customers, or limiting themselves to only having one or two major customers.
In 1991, the Aviation Distributors and Manufacturers Association (ADMA) published Aviation Industry Guideline on Bar Coding to address the growing problem of individual rules being set. This publication was the result of extensive research done by ADMA and the Air Transport Association (ATA), and outlined a homogeneous approach for the aviation industry to coordinate this technology. The final sentence given in the introduction of the publication read "The future is barcoding." Ironically, that was the last attempt by the ADMA or anyone else in the industry to attempt standardization for barcoding.
The reasons why facilities do choose to install barcoding capabilities into their operations are as diverse as the operations themselves. Some companies incorporate this technology into their operations for parts tracking and inventory, others use it to monitor labor time and costs, still others see this as presenting their business to customers in an efficient and professional light.
"Being able to present an itemized bill to a customer before they leave the facility, looks polished," says Leo Sawatzki, vice president - technical services for Atlantic Aero in Greensboro, NC. "It helps with cash flow and also allows us to go over the bill with the customer before they leave, in case there are any questions." Professionalism is also a key issue for Corporate Rotable & Supply in Ft. Lauderdale, FL.
"We pride ourselves in the way we present our equipment — how we package it and present it on the shelf," says Armando Leighton, Jr., the company's president. Corporate Rotable was an early adopter of barcoding technology and has had a system in place for seven years. They work closely with their computer support people to better utilize the hardware and software presently in place, as well as to plan for the implementation of new systems.
Leighton adds "It works well when you want to use it for a perpetual inventory count. On our repair side, technicians use a swish card [credit card-like instrument] to log time and job orders. It's more efficient and there is no clutter of paperwork."
Efficiency is a huge benefit of barcode technology. Barcoded data entry is much faster than handwritten or keyboarded data entry. While it may take only a few seconds to hand write a six- or seven-digit part number, you can scan twenty barcode digits in one second, and have that information entered immediately into a computer. The advantage of being able to scan so much at one time, also greatly reduces the amount of data entry errors. Industry studies have shown that operators will make one keyboarded data entry error for every 300 characters, or for example, one error per 50 parts or work order entries, while barcode scanning results in less than one error in 39,000,000 characters.
While it is frustrating and time consuming to search for errors, mistakes in data entry can also produce safety concerns. An incorrect part installed on an aircraft could lend itself to damaging that aircraft, or worse. Atlantic Aero's Sawatzki gives an example of how they avoid mistakes through "pick tickets." The maintenance technician wants a part or parts off of the shelf, so, he punches into the computer the necessary items and sends it to the parts department. The parts person scans the pick ticket produced for the required parts; any incorrect or invalid part numbers would immediately be found and could be corrected at that point. All parts would be collected from the stock room and placed together as one order on the pick ticket, saving time for all involved as several trips to the parts counter have now been eliminated.
Jack Demeis of Contiuum Applied Technology in Austin, TX, expands on the safety perspective.
"In addition to the efficiency and error reduction capabilities, barcoding provides 'cradle-to-grave' traceability of parts by allowing the operator to quickly identify the history of that part, including any servicing or modifications it has had."
Demeis continues, "Companies are really responding favorably to the capabilities afforded to them through barcoding and other types of inventory and maintenance tracking systems. A couple years ago, not many were interested in implementing barcoding, but now, those that weren't interested are taking another look to see how this technology can help their operations. There's been a tremendous response to the newer systems because of their ease of use."
This ease of use has been made possible by offering Windows®-based systems. Most people today have computers in their homes or have had some experience with computers and therefore are less intimidated by the look of the maintenance software packages.
"The terminology in the software we design is on-target with the industry," explains Demeis. "Technicians use the terms 'FAA-signoff' and 'squawk' — so does the dialog in the software. This common terminology helps those to give it a try who were maybe hesitant at first to use the system."
The hardware and software required for maintenance operations can vary. Whatever system your operation chooses to install, it is important to find a hardware/software support team that understands your unique business needs and goals. You need to have a fairly clear idea of the types of tasks necessary for your personnel and operations. This data will help the computer specialists better ascertain what will be the best system for your present and future technological requirements. You may want to have your personnel use hand-held scanners for remote applications, swish cards to monitor labor time and costs, or, if budget only allows for only a few computer terminals, you may need to install software that allows multiple users at one time.
Considerations for the proper types of printers also need to be evaluated. Certain printers, and the corresponding software, can only produce certain types of barcode labels. Some products in your inventory would require labels that are heat and chemical resistant, while others may need shrink tubing to mark wires or cables. Again, it is important to work closely with your computer support team to integrate the best systems for your operations.
While at present there is a lack of standardization in the industry for barcoding, the benefits of this technology rise above the standardization hurdle. The professionalism and efficiency associated with scanning technology and the cost savings in time and money, support the evidence that barcoding is the future.
Many thanks to those who offered information about barcoding for this article: Almetek Industries, Hackettstown, NJ, (908) 850-9700; Atlantic Aero, Greensboro, NC, (800) 334-2001; Bear Rock Technologies, Shingle Springs, CA, (530) 672-0244; Brady Worldwide, Milwaukee, WI, (414) 358-6600; Continuum Applied Technology, Austin, TX, (512) 918-8900; Corporate Rotable & Supply, Ft. Lauderdale, FL, (954) 972-2807; G&A Imaging, Hull, Quebec, Canada, (819) 772-7600; Inframetrics Inc., North Billerica, MA, (978) 901-8000; and Kroy Inc., Scottsdale, AZ, (602) 948-2222.
