Achieve cleanroom manufacturing traceability with custom tags

Manufacturing traceability is key to the success of any operation. Without it, production lines freeze up, quality falls, and safety regulations are broken. There are a number of tracking solutions out there, tags and labels being two of the most popular. But there’s a catch.

While tracking is equally essential in all manufacturing environments,  it’s a lot harder in industries whose processes take place in controlled environments like cleanrooms. Semiconductor and pharmaceutical manufacturers, for example, often find themselves struggling to find tracking solutions that protect the integrity of their clean environments, are durable under extreme temperatures and chemical exposure, and can be printed on site with tracking information. 

The reality is every manufacturer has a unique combination of requirements for whatever tracking solution they choose. No off-the-shelf solution is going to meet all of them. What you really need is a custom solution that’s designed to meet the specific needs of your manufacturing process and environment.

Why tags are perfect for tracking during manufacturing

There’s a reason tags are used so widely to track products as they move through the manufacturing process. Tags are simple, versatile, and dependable, making them an ideal solution when tracking failures just aren’t an option. 

Simplicity

Tags make it easy to identify items at a glance. Whether attached to a piece of equipment, a batch of raw materials, or a finished product, tags provide a clear visual marker, allowing workers and inspectors to quickly access the necessary information without needing to consult digital records. This is especially useful in cleanrooms or production environments where access to electronic devices might be limited.

Versatility

Tags offer a high degree of versatility, allowing manufacturers to adapt their labeling systems to different needs. Whether you need temporary tags that can be easily removed or more permanent options for long-term tracking, tags can be tailored to specific uses. They can also be customized on site with direct thermal or thermal transfer printing to include handwritten notes, barcodes, serial numbers, color-coding or any other information that assists with regulatory compliance and manufacturing efficiency. 

Dependability

Manufacturing environments, particularly cleanrooms, can be harsh. Tags can be customized to withstand extreme conditions, including high temperatures, chemical exposure, and frequent sterilization processes, such as autoclaving. A durable tag ensures that important information remains legible and intact throughout the production process, preserving manufacturing traceability even in the most challenging environments. 

Where to implement tags for optimal manufacturing traceability

Every manufacturing process is a little different — which is why the versatility of tags is such an asset for tracking. That said, there is also overlap in how manufacturing processes can be tracked using tags. You’ll find some of the most common uses below.

Equipment tracking

If you don’t know when a piece of equipment was last maintained or used, you can’t depend on it. That kind of uncertainty kills the efficiency of a manufacturing operation. Tags ensure the traceability of all of your equipment use and maintenance so that you can have confidence that your operations will run as intended. Tags can also contain vital information such as maintenance schedules, cleaning protocols, and calibration records. 

Material tracking

Knowing which materials are moving where and when is essential in any manufacturing process, and tags can get it done. Whether it’s a manufacturer in the pharmaceutical industry, tagging raw materials ensures they are used within specific timeframes and under the right conditions or a semiconductor manufacturer tracking sensitive materials through various production stages, tags ensure materials stay within their safety and use parameters.

Process monitoring

Knowing where an item is within your process is essential for everything from quality control to supply chain management. Take for example, a cleanroom environment where contamination control is essential. Tags can be used to mark different stages of the manufacturing process, ensuring that products adhere to clean protocols when appropriate. Or, in a pharma lab, sterility indicating tags can give confidence that a product has undergone sterilization and is ready to move to the next step in the manufacturing process.

Quality control verification

Ensuring product quality is one of the primary reasons for traceability. Tags make it easier to verify which items have passed through quality control checks, providing an additional layer of security for the production process. For example, in the biotech or medical device industries, tags are often used to signify that an item has been sterilized, passed inspection, or is ready for the next stage of production. This visual verification simplifies the quality control process and ensures that only approved products move forward.

Benefits of using tags for manufacturing traceability

Okay, you might be saying, but isn’t what I’m doing already probably good enough? It depends on what you think good enough is. The less precise your tracking, the more often your manufacturing processes will falter, the more quality issues you’ll have, and the more likely you are to fall out of regulatory compliance and incur fines. 

On the flip side, there’s a lot to gain from choosing a tracking method like custom tags that is tailored to your exact needs and dependable in its tracking performance.

Improved operational efficiency

Tags offer a quick and easy way to access essential information about materials, equipment, or processes without the need for extensive data entry or digital lookups. This speeds up workflows and reduces the risk of human error. Workers can instantly identify what stage of production an item is in or whether a piece of equipment is due for maintenance.

Enhanced visibility

In large or complex manufacturing environments, keeping track of everything can be a logistical challenge. Tags provide an additional layer of visibility, allowing you to keep tabs on all materials and processes, even when they’re spread across multiple production lines or facilities. This greater visibility helps you respond quickly to issues or disruptions, reducing downtime and waste.

Risk mitigation

Tags provide a physical record that helps trace potential issues back to their source, which is essential for risk management. If a product fails quality checks or a recall is necessary, tags make it easier to identify the affected batches and isolate them from the supply chain. This speeds up response time, reduces waste, and minimizes the impact of recalls on the overall production process.

Compliance with audits and regulations

Maintaining accurate records of production processes is crucial for passing audits and ensuring regulatory compliance. Tags provide a simple way to document the history of materials, equipment, and processes, creating an easily auditable trail. By using tags as part of a broader traceability system, you can ensure you meet industry standards and regulations without adding unnecessary complexity to their operations.

Tags are great — custom tags are better

Tags in general are a simple, effective path to manufacturing traceability. But if they’re not the right tags, you won’t get very far. 

Say you’re a medical device company, for example, whose product needs to go through IPA cleaning during manufacturing. If your tag can’t withstand that chemical exposure, then all the information it’s carrying becomes useless. 

There are a number of different factors you’ll want to think about when ordering tracking tags for your manufacturing processes.

Durability

What will your tags encounter during your manufacturing processes? High temperatures? Low temperatures? How low? Chemical exposure? Which chemicals? Sterilization? By identifying all of the harsh environments your tracking tags need to withstand on the front end, you’ll ensure you get a tag that holds up from the first step in your processes to the last. 

Clean or sterile compatibility

If your manufacturing process includes clean or sterile environments, then your tags will need to meet those same high standards. You’ll want to think about both the tag itself and the attachment method to ensure that your tags don’t introduce contaminants into sensitive areas.

Attachment options

Do your tags need to stay put long term or will you be removing them after a short time? Do they need to be reused? One of the strengths of tags is that there are lots of ways to attach them, from zip ties to wire. 

Size and shape

Depending on how you plan on using tags in your tracking process, size and shape can make a world of difference. Does a tag need to have plenty of room for handwritten information? Be small enough to not interfere with automated processes? Robust sample testing goes a long way in these decisions.

Printing

Pre-printed tags can save a lot of time and resources, while on-site printing and handwriting options ensure up-to-the minute information is included on your tags. Knowing whether you want fully pre-printed, partially pre-printed, or blank tags is important when choosing the right tag for your needs.

Expert-engineered custom tags take the guesswork out of manufacturing traceability

Juggling all of these tag options can be overwhelming, and getting the combination right is essential for achieving manufacturing traceability. 

CleanMark’s expert tag and label engineers have experience in high-tech industries like pharma and semiconductor manufacturing. Their job is to research every detail of your tracking needs and then to design a solution that is efficient and dependable. 

And, we remain your tag and label partner as your manufacturing processes evolve, ensuring that you can track your products reliably from start to finish.

Want to learn more? Schedule a consultation with one of our label engineers today.