Unfortunately, there may not be a quick solution that will solve every ‘scanning’ problem, but this may help you get started.  Disclaimer – There are lots of methods to solving problems and this is only one way.  The term ‘customer’ used here could be an internal or external customer.

• If this is a problem that just started to show up in an otherwise smooth running scanning process then the first question should be ‘What has changed?’, ‘What is new?’
• If you are not sure if you have a scanner problem or a printer/barcode problem
  • Most ‘scanning’ problems are really problems with the barcode and not the scanner – perhaps 80%+, You can close in on the real problem by using the following analytical sequence:
    • See if the scanner will scan a different barcode of the same type.
      • If it can’t scan different barcodes of the same type then it may be a scanner issue.  Perhaps the scanner is not configured to scan that type and needs to be reconfigured or does need to be serviced.
      • If it can then the probability is even higher that it is a barcode problem – perhaps 95%.
      • Look at the barcode to see if there is visible problem – line, blemish, smear, crease, etc
        • If you can’t see anything wrong with it then you will need to use a barcode verifier to determine what specifically the problem is and what corrective action to take
• If your customer told you that your barcodes are substandard
  • and sent you a report from a verifier – this makes it easy to figure out. Use their report to find the barcode parameter that has the lowest grade and refer to the ISO Tutorial – this will give you the details on what is happening
  • but did not send you a report from a verifier – you will need to have your barcodes evaluated using a barcode verifier. This is the only way to really analyze the barcode parameters effecting quality and readability.
• If you have a ‘rare’ complaint that your barcodes are ‘hard’ to scan or can’t scan
  • This is a classic general quality issue that impacts barcode applications as well.  Most people feel that if they are not getting any complaints that everything is ‘fine’.  They do not have a measure of their actual quality level, just that everything is ‘fine’.  This is an indicator of a reactive approach to quality compared to a proactive approach.   Generally, people are beginning to realize that a proactive approach gets them a step ahead and avoids problems rather forcing them to react and ‘put out fires’ all the time.  They also realize that even if they do not hear the customer complain too often, the customer may be having better success with a competitors product. The solution is to be proactive.  Look at Good manufacturing practices.
  • Try to get a sample of the barcode they are having trouble with.  Verify it and refer to the ISO tutorial for an explanation and possible solutions.
• Remember a few things:
  • Barcode problems are predictable and preventable (GMP)
  • The 1, 10, 100 rule – prevention cost is $1, cost to fix a problem batch before it gets out the door is $10 and ignoring the problem will cost $100     https://totalqualitymanagement.wordpress.com/2009/02/25/what-is-1-10-100-rule/
  • Get some help if you feel you need it – there are many out here that can help
  • Attack the problem and solve it quickly to demonstate you care