4.5 Scanning, Databases & MES Links

Scanning and data integration are where physical marks become actionable traceability.traceability. ReadersThis onis the linedigital capturebackbone everythat ID,transforms whilea APIs stitch those scansbarcode into an audit trail. By wiring readers directly to your MES and(Manufacturing ERP,Execution creatingSystem), you create a continuous threadrecord from the raw panel to the final shipped box.box—turning Aan minimalRMA setinto a quick database lookup instead of well-placed scan gates—panel-in, marking, depanel, test, and pack-out—ensures genealogy builds itself without slowing production. With a cleancostly dataphysical model and guardrails against duplicates or mis-sequenced scans, every unit’s story is preserved in seconds, not spreadsheets. The result is a calm, predictable line and instant visibility when returns or audits strike.investigation.

4.5.1 The Scan Gate Lineup: Where to Collect Data

You don't need a scanner at every machine, but you must have scanners at the minimum points required to bind the product's identity to its key process events.

A. Reader lineupLineup (what lives where)

Hardware)

• Fixed-mountMount 2D imagersImagers: Use these at automated stations (like stencil print or pick-and-place inflow) that mustdemand neverspeed missand (panelconsistency. They capture the Panel or Unit ID ininstantly atas SMT;the unitboard SN after laser/label).passes.
• Handheld 1D/2D Scanners: Ideal for flexiblemanual spotsprocesses (rework cells, debug benches, final pack-outout). exceptions).
• In-processThey verifiersoffer nearflexibility printers/markers to grade freshly printed/lasered codes and block bad ones. All readers should speakwhere the sameoperator symbologiescontrols youthe froze in 4.3 and write results straight into timing.MES/ERP via API.
  

4.5.2

B. WhereMinimal toScan scan in the routePoints (minimalThe butRequired sufficient)

Gates)

Wire these scan points into the MES route/operations/WIP statesroute so the system forces the right code is requiredaction at the right moment.time:

• SMTScan panelPoint	Item in:Scanned	Purpose
  Panel-In (Start of SMT)	Panel scanBarcode panel barcode (on the rail)	railsStarts Genealogy: Binds the Work Order (stable, easyWO) to hit)the physical panel.
  After Marking (Laser/Label)	Unit 2D Code	Binds Identity: Verifies the new Unit SN is readable and writes the first critical record to startthe genealogy.database.
  AfterDepanel/Breakaway	Panel markingID, (laser/label):then individual Unit SNs	Splits the Record: scan/verify unit 2D to bind SN ↔ panel/WO/BOM rev and writeCreates the record."Panel (Ties$\rightarrow$ toUnits" 4.2–4.4.) Depanel:split scanrecord panel ID then each unit SN to createin the database.panel→units split record.
  Test (ICT/FCT):	Unit SN	Records Verdict: stationWrites readsthe SN at start, writes results at end (pass/fail, test limits, and firmware rev).version Failuresto auto-the unit’s record. Fails automatically open repair tickets.tickets.
  Final pack-out:Pack-Out	Unit SN – Box Label	Closes the Loop: scanLinks unitthe SNindividual → print/scan box label → post shipment record that links box↔unit(s) to the final customer shipping ID/Box ID.

  4.5.2 Data Architecture: MES, APIs, and the Core Model

  Traceability only works if the scanned data instantly updates a central system (MES/ERP). This “closesrequires a clean, simple relational database model and clear communication protocols.

  A. The Few Tables That Matter

  Your system needs to be relational, linking every event back to the loop”single sosource aof returntruth: canthe jumpUnit straightSerial to its full build/test history.
  

4.5.3 Data modelNumber (the few tables that matter)SN)

Keep it simple and relational; these keys unlock fast RMAs and clean audits..

Object	Primary key(Key(s)	Joins toTo	Why it mattersPurpose
WorkOrderUnit	SN	WOPanelID, BOMRev	Panels,The Units	Scopestar quarantinesof genealogy; holds core identity and yields.configuration.
Panel	PanelID	WO, Units	Bridges line scans before depanel.
Unit	SN	PanelID,depanel WO,splits BOMRev	Thethe starproduct of genealogy and returns.flow.
ScanEvent	(SN/PanelID, timestamp)Timestamp)	Unit/Panel	Who/when/Records the physical who, when, and where of every code was read.scan.
TestResult	(SN, station,Station, run)Run)	Unit	Pass/Stores every test pass/fail, limits,measurement, firmware—hooksand torepair repair.hook.
MaterialLot (optional)	LotID	Unit (critical parts)	Component-levelTracks genealogycritical component lots (BGA, FETs) when required.
Shipment	BoxID	Units	Links box labels to unitsrequired for customers.full genealogy.

B. API Patterns (How Stations Talk)

DashboardsAutomated stations and alertsscanners readcommunicate fromwith thesethe sameMES/ERP tablesusing clear, lightweight commands (APIs) to watchensure earlydata lotsis after changes.

4.5.4 API patterns (how stations talk to systems)

You don’t need a complex bus—just clear callsconsistent and webhooks:sequenced correctly:

• POST /scan {code, type, station, op, timestamp}: →The basic log event. MES validatesuses this to validate the opstation and advancesadvance WIP;the rejectsWork wrongIn codes.Progress (WIP).
• POST /test-result {sn, station, verdict, params}: →Logs logstest toresults and, on a 'FAIL' verdict, TestResult and (on FAIL) auto-opens a repair ticket. for the unit in the repair loop.
• GET /label-data?sn=…...: →Returns returnsthe customer-facing fields (SN, BOM rev,rev) config)from the ERP for printing final box labels; ERP link adds ship-to/order info.
• Webhook: unit-ready → pack-out printers subscribe and print labels only for good units.
  labels.

4.5.53 Guardrails and Closure: Making Bad Data Hard

Traceability systems are useless if the data is faulty. You must build quality checks (makeguardrails) into the system to prevent bad data hard)from being logged.

A. Data Guardrails

• Grade beforeBefore accept:Accept: The marking stationsstation must verifygrade the code quality and(Chapter 4.4). If the grade is poor, the MES must block WIP onuntil failurea (yourclean 4.4code gate).is applied.
• Duplicate & formatFormat checks:Checks: MES rejectsmust reject reused SNs, wrong revs,BOM revisions, or scans that are out of sequence based on the active operation.production operation (e.g., rejecting a 'Depanel' scan if the unit hasn't passed 'Test' yet).
• Store-and-forward:Forward: readersScanners must buffer data if the network connection temporarily drops, then replay the logs once the connection returns. This prevents operators from resorting to paper or shadow spreadsheets when the network blips, then replay; no side spreadsheets.blips.
• Operator feedback: short, colored station banners/alerts help leads react fast to scan/test spikes.
  

4.5.6

B. “"Board to box”Box" Proof (Closing the Loop)

The ultimate proof (whatof a clean recordtraceability lookssystem like)

is

Giventhe anability SN,to youinstantaneously shouldgenerate pulla incomplete seconds:

unit

• WO/line/shift, panel ID & depanel mapping, every scan event, ICT/FCT logs, rework/repair records, and box/shipment data—one storyhistory from the first rail scan to thefinal shipping label.
  That’s
  • Given a customer return (SN or Box ID), the definitionsystem should be able to pull, in seconds: the WO, the SMT line, every test log (ICT/FCT), any rework/repair notes, and the final box/shipment data.
  • This means the MES and ERP are successfully linked: the ERP handled the shipment, but the MES provided the entire build and test history. This instantaneous lookup is the fundamental ROI of closingyour thetraceability loop.
    system.

  4.5.7 Release checklist (print this)

  • Readers placed at panel-in, mark verify, depanel, ICT/FCT, pack-out.
  • MES route/ops/WIP require the right scan at each step.
  • APIs live: /scan, /test-result, /label-data; ERP link for shipments.
  • Repair tickets auto-open on test fails; dashboards watch early lots.
  • Panel rails reserved for codes; scanners can hit them fast.

    
    

  
  

  ---

  Conclusion: Installing the right readers, wiring them to MES/ERP via lightweight APIs, and enforcing verification at key gates closes the loop from board to box. The benefit is precise, reliable genealogy that turns RMAs into quick lookups instead of costly recalls.