5.21 Labels, Manuals, and Regulatory Markings

Final identification is the last critical step in the assembly process, transforming the completed product into a traceable, compliant, and market-ready unit. The placement and durability of labels, manuals, and regulatory markings are non-negotiable mandates that must satisfy three audiences: the customer (instructions), the installer (identification), and regulatory bodies (safety compliance). Errors in labeling lead directly to regulatory failure, shipment rejection, and loss of warranty traceability.

5.3.21.1 Regulatory and Traceability Mandates

Compliance markings are mandatory legal statements. All data that changes per unit (dynamic data) must be printed from the MES and verified.

A) The Rating Plate and Legal Identity

The Nameplate (or Master Label) must be permanently affixed and contain all essential, static, and dynamic data:

Legal Identity: Brand/manufacturer, model, PN, Class symbol (I/II), and SN.
Mains Data: Input V/Hz/A or V/⎓ (DC/AC).
Regulatory Set: Marks like CE/UKCA, FCC/IC, RCM, UL/cTUVus (as required by region). These icons must be the correct size and color.
RF IDs: If the product uses modular approval, the exact regulatory wording and IDs must be printed or included in the manual per regional rules.

B) Dynamic Data and Barcode Protocol

Traceability: The unit Serial Number (SN) must be printed along with the Date/Lot code, and optionally the firmware revision.
Network IDs: Unique identifiers such as MAC/IMEI must be captured and printed.
Barcode Mandate: Use DataMatrix ECC 200 or QR for 2D codes. The grade must target ≥ C (2.0) per ISO/ANSI verifier. Ensure a quiet zone of ≥ 1 cell is maintained on all sides. Prohibited: Placing barcodes under clamps or on high-curvature surfaces.

5.3.21.2 Material, Durability, and Placement Protocol

Placement must be precise and the materials must withstand the product's full environmental range (UL 969 mindset).

A) Material and Print Mandates

Face Stock: Polyester (PET) for most chassis (solvent/heat resistant); Polyimide near hot zones. Tamper-evident PET is used for warranty seals if contractually required.
Ink: Use Resin Thermal Transfer ribbon or UV inkjet (prohibited is wax ribbon). Overlamination is required in harsh environments (harsh cleaners).
Adhesive: Choose high-tack acrylic adhesive matched to the surface (e.g., LSE grade for certain plastics).

B) Placement and Adhesion Check

Datums: Locate labels to edges/holes (datums) with a tolerance of ± 0.5 – 1.0 mm and ≤ 1˚ skew. Prohibited: Placing labels over screw heads, seams, or gasket lands.
Surface Prep: The surface must be warm (≥ 15 – 20˚C) and wiped clean. Apply pressure with a squeegee/roller for 3 – 5 seconds to ensure proper adhesion dwell.
Durability Checks: Sample labels must pass a 10 x IPA rub and tape-pull test (no smear, lift, or curl).

5.3.21.3 Documentation and Final Verification

Physical and electronic documentation must match the final product revision and target region.

A) Document Control and Content

Manuals: The manual revision must match the product revision in the MES. Language sets must be defined by the SKU/region.
Content: Manuals must include safety, installation, regulatory statements, warranty, and disposal (WEEE/RoHS).
Special Marks: Print symbols (e.g., PE (⏚), Hot Surface) only when the design and test evidence support them.

B) Final Verification and Audit

2D Verification: The 2D barcode must be scanned upon packing. The station must verify the grade is ≥ C and the scan opens the exact SN record in the MES.
Region Control: Audit confirms the regulatory set on the product (CE/UKCA/FCC) is correct for the shipped region.
Acceptance Cues: The rating plate must be readable, complete, and aligned with no missing fields or skew > 1˚.

Final Checklist

Mandate
Criteria
Verification Action
Regulatory Set
All required icons (CE, UL, FCC) present; final SN/MAC printed.
MES verifies template matches SKU/Variant for the target region.
Durability
Labels pass 10 x IPA rub and tape-pull test (no smear/lift).
Material (PET/Polyimide) and Resin Ink verified; applied with roller pressure.
Placement
Datums aligned within ± 1.0 mm; label does not cover seams/vents.
Surface cleaned and warmed (≥ 15˚C) for proper adhesion.
Traceability
2D barcode scanned and verified Grade ≥ C; SN linked to MES record.
Audit confirms SN on the product matches SN on the carton/MES.
Security
Tamper-evident seals used only where contractually required.
Labels are not placed over screw heads unless mandated for warranty.
Documentation
Manual revision and language set match product revision and region.
Packaging instruction mandates inclusion of all documentation.

Mandate	Criteria	Verification Action
Regulatory Set	All required icons (CE, UL, FCC) present; final SN/MAC printed.	MES verifies template matches SKU/Variant for the target region.
Durability	Labels pass 10 x IPA rub and tape-pull test (no smear/lift).	Material (PET/Polyimide) and Resin Ink verified; applied with roller pressure.
Placement	Datums aligned within ± 1.0 mm; label does not cover seams/vents.	Surface cleaned and warmed (≥ 15˚C) for proper adhesion.
Traceability	2D barcode scanned and verified Grade ≥ C; SN linked to MES record.	Audit confirms SN on the product matches SN on the carton/MES.
Security	Tamper-evident seals used only where contractually required.	Labels are not placed over screw heads unless mandated for warranty.
Documentation	Manual revision and language set match product revision and region.	Packaging instruction mandates inclusion of all documentation.