In the intricate dance of warehousing and manufacturing, the goal is to optimise every step of the production process. One integral step, often understated but critical in ensuring quality control, is check-weighing. With the rise of automated processes, industries, particularly those in warehousing, distribution, and manufacturing, have adopted this measure widely. In this piece, we’ll delve deeper into the concept of check-weighing and explore its application in a conveyor system developed by Conveyor Systems Ltd (CSL) for a 3PL.
What Exactly is Check-Weighing?
Check-weighing is an essential quality control measure practised in numerous industries. It primarily concerns weighing goods at diverse stages during the production or distribution process. The goal? To confirm that they align with stipulated weight requirements. For many, this process is not only automated but also seamlessly integrated into conveyor systems to bolster efficiency and uphold the highest accuracy standards.
Application in CSL’s Conveyor System
In the context of a recent CSL designed and installed conveyor system for a 3PL, the objective was clear: validate the weight of each handled carton. Here’s a breakdown of how the check-weighing process intertwines with the system:
- Carton Induction: After manual packing and the application of a carrier label on the carton’s top face, induction into the conveyor system follows.
- Weighing: Each carton, whilst on its journey along the conveyor, crosses a check-weigher. This tool, an integrated high-precision scale, registers the weight of cartons in real-time.
- Weight Validation: An essential link exists between the check-weigher and the Warehouse Management System (WMS). The WMS, privy to the anticipated weights of cartons, juxtaposes this with the real-time weight recorded by the check-weigher.
- Data Communication: Both the weight data and the barcode information, gleaned by a top-reading barcode reader, are relayed to the WMS. This integral step ensures the WMS can monitor and validate the packing process’s precision.
- Quality Assurance (QA) Diversion: Discrepancies do occur. If a carton’s weight strays from the expected—breaching a certain tolerance threshold—the conveyor system instinctively reroutes it to a distinct QA lane. This lane serves as a checkpoint where cartons can undergo manual verification, repacking, or even removal. The outcome? Only cartons that meet stringent packing criteria proceed along the conveyor to the concluding sortation lanes.
The Resultant Benefits
By weaving the check-weighing process into its fabric, the CSL conveyor system champions accuracy, minimises errors, and refines the entire journey from packing to dispatch. Such meticulousness not only enhances operational efficiency but also fortifies the 3PL’s trust in the system’s reliability.
Frequently Asked Questions (FAQ) on Check-Weighing
1. What industries typically use check-weighing?
Many industries utilise check-weighing, but it’s predominantly found in warehousing, distribution, and manufacturing sectors.
2. Why is check-weighing important in a conveyor system?
It ensures each carton or product meets specific weight requirements, enhancing quality control and reducing the possibility of errors.
3. What happens if a carton doesn’t meet the expected weight?
The conveyor system automatically diverts it to a QA lane for further inspection and necessary corrective actions.
4. How does check-weighing improve the overall operational process?
By validating weights, it reduces errors, ensures products meet standards, and streamlines the packing to dispatch process.
Incorporating such a rigorous system as check-weighing in the operational cycle illuminates a company’s commitment to excellence, ensuring clients receive the quality they expect and deserve.
Creating relationships that last
We are proud to have completed installations over more than 25 years for many major organisations. We have forged strong relationships and continue to provide automation solutions through ongoing maintenance or follow-on projects. Constantly working with our customers to meet and exceed their needs.
"I have found working with CSL the ideal partnership, they understood the brief and worked closely with CEF to ensure the design met all of the criteria. The support from start to finish was excellent. The project ran smoothly from start to finish. The system has made our new warehouse very efficient and allowed us to increase the throughput"
“As this was a new facility it was difficult to visualise the conveyor system prior to the mezzanine floor installation, but CSL provided a detailed 3D drawing which included both the mezzanine and the conveyors which brought clarity to this. The install process was smooth and the end results have allowed us to increase control, flexibility & volumes”
“We have worked with CSL previously and after many years of reliable operation we decided to use CSL again to design, supply and carry out the installation. As with the last system the benefits became almost immediately evident”