Problems on this page:
Serial numbers not printed or unreadable
Hits OEE: Quality
Symptoms: Packs reach the camera with missing, smudged or unreadable serialised codes and are rejected.
Printer head dirty or ink low
Clean the print head and check the ink or ribbon level as the printer maker specifies.
Pack surface varnish or coating rejecting the ink
Check the ink and the pack coating together and test a new carton lot before use.
Print position drifting with conveyor speed
Check the print trigger and the encoder that follows the conveyor speed.
Camera grading set too strict for the code size
Check the grading settings against the code specification agreed for the market.
Prevention: Code grades reviewed per batch from the camera records.
Serial number pool or batch data errors
Hits OEE: Availability
Symptoms: The line stops because the system cannot get serial numbers or the batch data does not match.
Serial number pool not requested in time
Request the number pool from the site or enterprise system before the batch starts.
Batch data entered wrongly at the line
Check product code, batch and expiry data against the batch record before release.
Network connection to the site server lost
Check the network link and the server status.
Product master data changed without updating the line
Check that the product master in the line system matches the site system.
Prevention: Batch set-up checked by a second person before start.
Aggregation errors between pack, case and pallet
Hits OEE: Quality
Symptoms: Case or pallet records do not contain the right serial numbers, and the aggregation must be repaired.
Packs added or removed by hand after scanning
Train operators on the rework procedure so every manual change is recorded in the system.
Case scanning missing packs in a layer
Check the case aggregation camera field of view and lighting.
Rejected packs not removed from the record
Check that every reject is decommissioned in the system.
Line clearance not completed between batches
Complete the line clearance so no pack from the last batch stays on the line.
Prevention: Aggregation reconciled at batch end.
Reject rate high at the verification camera
Hits OEE: Performance
Symptoms: The camera rejects many packs that look acceptable to the operator.
Lighting or camera position moved
Check the camera mounting and lighting against the validated set-up.
Reflections from shiny packs
Adjust the lighting angle or use the diffuse lighting the maker recommends.
Code too close to a pack edge or crease
Check the print position for each pack size.
Line speed above the validated speed
Run at the validated speed or validate the higher speed.
Prevention: Reject reasons trended per batch.
Batch reports not reaching the site system
Hits OEE: Availability
Symptoms: The batch cannot be closed because its serialisation report is missing or rejected.
Interface queue stuck
Check the interface status between the line and the site system.
Report contains numbers that were not commissioned
Investigate and correct the aggregation before re-sending.
Time stamps or user records missing
Check the audit trail settings on the line system.
Report format changed after an update
Check the report format after any software update.
Prevention: Report status checked before the batch is released.
Tamper-evident label not applied
Hits OEE: Quality
Symptoms: Cartons pass without the tamper-evident label or with it misplaced.
Label applicator out of labels or web broken
Check the label reel and the web path.
Applicator timing wrong for the carton size
Set the label position for each carton format.
Label sensor dirty
Clean the label gap sensor.
Presence check camera not active
Check that the presence check is switched on in the batch recipe.
Prevention: Tamper-evident labels checked on samples each hour.
Changeover between products taking too long
Hits OEE: Performance
Symptoms: Product and market changes on the serialisation line take long.
Market templates not prepared
Prepare and approve the market templates before the change.
Line clearance done slowly
Use a written line clearance checklist with clear roles.
Camera and printer settings set by trial
Store validated settings per product.
Waiting for quality release of the set-up
Plan quality staff availability for changeovers.
Prevention: Changeover time recorded.
System validation drift after changes
Hits OEE: Quality
Symptoms: Changes to the system are made without the required change control.
Settings changed locally
Restrict access to settings by user level.
Updates installed without testing
Test updates on a non-production system before installing them.
Audit trail not reviewed
Review the audit trail on a set schedule.
No record of approved settings
Keep the approved settings as a controlled document.
Prevention: Audit trail reviewed monthly.
Guidance only. Always follow lockout/tagout and your site's safe-work procedures, and verify against OEM manuals before acting.
Related equipment guides: inkjet coder · vision inspection · cartoner · print and apply labeller · barcode scanner
Stop the same fault coming back
Recurring serialisation system stops usually trace to a cause you cannot see by hand. The partner we recommend is Fabrico: it tracks OEE and downtime live from PLCs, IoT sensors or AI cameras; where cameras are fitted, the video of a stop sits next to its machine data so the cause can be reviewed; and a technician opens the work order from the stop in the same system. Data is hosted in the AWS EU region, and Fabrico and the company behind it hold ISO/IEC 27001, ISO/IEC 20000-1 and ISO 9001.
Book a Fabrico demo
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Related tools: full troubleshooting directory · OEE calculator · downtime cost · MTBF / MTTR · glossary
Methods that cut recurring stops: the six big losses · root cause analysis · preventive vs predictive maintenance · TPM · SMED & changeover