Hunkar Data and Barcode helps manufacturers and distributors around the world dramatically improve their profitability, quality and cost competitiveness. Hunkar specializes in: Inventory Control Systems, Asset Management, Line Automation, Mobile communication and tracking, Bar code and Prime Label Printing, Custom Labels, Label Applicator Systems, Wireless Infrastructure, Vision Systems, Custom Programming, General Data Management and related Storage and Security.

Asset Tracking


Problem:

A public vocational school system had multiple locations with assets that needed to be tracked for insurance, accounting, and funding purposes. Each year a state inspection team would descend upon the school’s administrative offices, comb through the asset inventory lists, then randomly pick assets that they needed to see and verify. Stated asset values were also checked against current depreciated values. Portable assets would sometimes travel from class to class, or student to student, which made the verification process very tough. The state inspection team usually spent three weeks working within this one vocational school system.

Solution:

All data transaction files are kept in a Microsoft Access or SQL database fed by the Hunkar Asset Management applications. Hunkar provided system analysis, the database design and development, as well as the data collection system design and implementation. By utilizing the open database structure, changes or additions to the data collection system or interfaces to other systems are easily accommodated for the future. All data transactions are date and time stamped at the data collection point. All data uploads are date and time stamped and tied to a user identity. The system includes appropriate user interfaces, basic reports and first year’s software maintenance.

Benefits:

  • Eliminate the labor required to hand write receiving information.
  • Eliminate data problems and errors from illegible, misinterpreted, or transposition errors.
  • Eliminate not knowing where each item is located.
  • Reduce labor required to validate accurate inventories.
  • Accurate asset inventories and updated values.



Label media


Problem:

Inventory was marked and recorded by hand on manufactured and purchased components used in the assembly of complex equipment utilizing information created in-house on a MS Excel spreadsheet. The spreadsheet included part, drawing, and finished assembly numbers. Mis-marked components would often be used in the fabrication area, creating the need for rework all the way back to the earliest stages of production. On-time deliveries suffered due to rework delays and cost margins were becoming uncompetitive.

Solution:

Hunkar surveyed the facility and installed a powerful off-the-shelf label design and bar coding software package, along with strategically located printers and portable handheld computers with scanning capabilities. The label system used the client’s existing MS Excel database to provide data for both the human-readable and bar code content of the label. All raw inventory was coded and checked against the specific purchase information. Cut parts are now labeled as they are produced with the job number, drawing number and task ID to make certain they are properly fabricated into correct assemblies.

Benefits:

  • Order and inventory data are up to date.
  • Significantly improved production time due to low need for rework.
  • Consistent production quality now requires less Quality Assurance staff and rework monitoring.
  • Productivity improved due a reduction of short runs to replace missing or misused material.
  • Profit margins increased due to lower costs associated with re-work and scrapped material.



Inventory Tracking


Problem:

High volumes of various products, many of which are physically similar and time sensitive, must be moved from manufacturing to finished goods and then retrieved for loading and shipment. Currently personnel have problems finding all of the products for the orders, causing revenue loss and production time loss. Additionally, the plant experiences short manufacturing runs to replace material that cannot be located. This often results in inflated inventory levels to cover inaccurate inventory quantities. One incorrectly shipped pallet may generate $1,100 in unnecessary costs.

Solution:

The Hunkar Production Server automatically links printer applicators directly to the client's manufacturing system generating bar codes that will be scanned in the pallet loading area to make certain the correct product(s) are loaded on the correct pallets for shipment. All pallets are given a unique ID including specific pallet location quadrants. Paperwork is replaced with hand held terminals for picking, staging, loading and shipment validation.

Benefits:

  • Order and inventory data are up to date.
  • Invoice time is significantly reduced resulting in improved cash flow.
  • Correct product was palletized and the pallets shipped to the correct location.
  • Productivity improved due to lack of emergency short manufacturing runs to replace missing material.
  • Profits increased due to lower costs associated with incorrectly shipped pallets and fire fighting.



Integrated Production Management


Problem:

Mis-marked cartons at the manufacturer caused problems through the retail level, including potential product liability hazards. The result for the manufacturer was a string of product rejections, credits, return shipments and significant lost production time.

Solution:

Hunkar Production Tools enabled each production line to be equipped with a scanner and smart printer. Scanning the bar code from a shop order and from a raw material tag assured that the correct label was now produced for the associated product. The product data was retrieved for label content, raw material validated, and each carton full of products assigned a unique identity. All subsequent pallets of products were identified and accurately labeled with the finished goods transactions fed to the manufacturing system, including downtime reports for each manufacturing line. All cost effectively accomplished without a PC or other terminal in the network.

Benefits:

  • Product is accurately labeled and shipped.
  • Customer complaints diminished to nothing.
  • Productivity increased due to lack of lack of returns, which boosted revenue.
  • Exorbitant costs of error handling, shipping, and corrective actions were eliminated.
  • Floor space used to pre-label cartons became available for improved productivity.



Label Applicators


Problem:

Boxes full of product had been hand labeled for years as they slowly traveled down the conveyor toward the shipping area. Sometimes the people doing the labeling placed wrong labels on boxes, and the shipments would go to the wrong location or to the right location with the wrong product. In time, customer demands became more challenging, and business volume stressed the manual work procedure to its maximum. The relationship of wrong shipments grew along with the business, but so did financial penalties from clients. “One wrong box on this truck and we are sending it all back”, were the demands now being routinely heard. Freight costs and order remakes were eating up productivity and profits. The company needed a reliable solution.

Solution:

Hunkar installed an automated scan-and-print shipping label application system. Job numbers, product numbers, and order information were bar coded and applied to the cartons at the time they were loaded. The orders were now automatically sorted downstream using fixed scanners that transmitted to the order database and diverted cartons to the appropriate spur for palletizing. The products at the end of each spur were palletized, shrink wrapped and labeled. The label on the outside of the shrink wrap now has the dock number for the truck traveling to the appropriate customer.

Benefits:

  • Cartons were accurately marked.
  • Orders were sent to the correct location.
  • Customers receiving the product spent significantly less time verifying orders.
  • Shipping costs reduced significantly.
  • Profits increased due to lower costs associated with eliminating incorrectly shipped pallets and product.
  • Financial penalties and returned shipments reduced to an insignificant level.



Mobile Enterprise Systems


Problem:

Orders were received daily at the home office and then sent to the scheduling department to be placed on sheets for pick-up twice a week. The route personnel turned in completed orders then loaded their vehicles for the next route(s) and delivered to customers. Customers often placed their next orders with drivers during delivery and/or required that an inventory be taken for replenishment stock. Signed delivered order receipts were occasionally lost or left in the vehicles, delaying billing and collections. Problems plagued the system due to incorrect items and quantities checked on the order forms, or the wrong items delivered to customers. Notes about the special needs of customers were often illegible and disregarded. Customer dissatisfaction grew while sales fell.

Solution:

A Hunkar Mobile Enterprise System was installed providing each line item on the order form to be bar coded and all route personnel outfitted with a hand held portable PC with scanner. New orders were accurately scanned and immediately transmitted to the home office for processing. Deliveries were signed and transmitted for immediate billing, significantly improving the company’s cash flow. New order requests would be immediately entered by drivers for future deliveries and client inventory records became available real time. Customer satisfaction is greatly improved.

Benefits:

  • Product is accurately shipped.
  • Customer complaints diminished to nothing.
  • Significantly improved profit and new sales due to immediate delivery notification.
  • Improved productivity and added capacity.