Implementing Barcode Systems in Manufacturing: Efficiency Unleashed

Implementing Barcode Systems in Manufacturing

Implementing barcode systems in manufacturing is an excellent idea for more than one reason. The typical benefit is that it will help make keeping track of your inventory so much easier, but like we said, there are more. It’s when you try to figure out which type of system you should implement and how that you start to hit some roadblocks.

But fear not; we are here to help make the process easier for you. We will first cover what a barcode system is and the types there are so that you know what your options are. After that, we will take you step by step on implementing the barcode system in your manufacturing process. To round up the article, we will go over the benefits you might enjoy and the challenges you might face.

What Is A Barcode System In Manufacturing?

A barcode system in manufacturing is like a high-tech tag for products. It’s a way of using those black-and-white lines (barcodes) you see on items to keep things organized. Imagine it as a super-smart label that helps factories and businesses keep track of products from when they’re made to when they’re sent out. This system makes the manufacturing process faster, reduces mistakes, and helps everyone know exactly where things are in the production process.

Types of Barcode Systems in Manufacturing

One of the first decisions you need to make if you want to implement a barcode system in your manufacturing business is to select the right type of barcode system. Many options are available for you, and we will go over three of the most common ones. They are:

Linear Barcodes

Linear barcodes are the traditional, one-dimensional barcodes you often see on product labels. They consist of vertical lines of varying thickness and spacing. These barcodes encode information like product numbers and are scanned using laser or CCD scanners. Linear barcodes are simple and widely used for inventory tracking, retail, and apparel manufacturing in Bangladesh. Here are some common ones and their uses:

  • Code 128: Versatile and data-dense, commonly used for product identification in manufacturing.
  • Code 39: Simple and reliable, ideal for labeling and tracking products in manufacturing processes.
  • UPC (Universal Product Code): Widely used in retail and manufacturing to uniquely identify and track products.
  • EAN-13 (European Article Number): Similar to UPC, it is commonly employed for product identification and tracking, especially in international trade.
  • GS1 DataBar: Efficient for encoding more information in a smaller space, valuable for labeling and tracking items in the manufacturing supply chain.

2D Barcodes

Unlike linear barcodes, 2D barcodes can store information horizontally and vertically, packing more data into a smaller space. QR codes are a typical example of 2D barcodes. They’re versatile and can store various data types, such as web links or product details. 2D barcodes are popular for mobile scanning applications, providing quick access to information with a simple scan.


RFID (Radio-Frequency Identification) tags use radio waves to share data between a tag and a reader. These tags consist of a microchip and an antenna, allowing them to store and transmit information. RFID technology is commonly used for tracking and managing inventory in real-time. Unlike barcodes, RFID tags don’t require direct line-of-sight for scanning, making them efficient for various applications, from retail to manufacturing.

Guide to Implementing Barcode Systems in Manufacturing

Now that you have figured out the options you have available to you, we will be going over how you can implement barcode systems in manufacturing.

1. Assess Your Needs

Identify the specific areas in your manufacturing process that can benefit from barcode technology. This could include inventory management, order processing, quality control, and shipping.

2. Select Barcode Types

With a clear idea of where you need to use your barcode system, you can narrow down your choices for the system. For example, the most common barcode systems in clothing manufacturing are Code 128 and 39. 

3. Invest in Barcode Scanners

Select suitable barcode scanners based on your requirements. Consider factors such as scanning speed, connectivity options (USB, Bluetooth), and compatibility with your existing systems if you have them.

4. Barcode Printing

Invest in quality barcode printers that can produce durable and high-resolution labels. Ensure that the labels stick to your products or inventory items properly.

5. Integrate with Existing Systems

Integrate the barcode system with your existing enterprise resource planning (ERP) or manufacturing execution system (MES). Doing so will allow you to maintain data flow on all production levels in your manufacturing plant.

6. Implement Barcode Software

Get software that helps you quickly design, print, and manage barcode labels. It should also update information in real-time and generate useful reports.

7. Create a Database

Develop a central database to store information linked with each barcode. Information may include product details, manufacturing dates, lot numbers, and other relevant data.

8. Employee Training

Train your staff on how to use the barcode scanners and software. Ensure they understand the importance of correct data entry and how it impacts your manufacturing process.

9. Pilot Testing

Once everything is set up, you need to do a pilot test in a controlled environment. The test will help you determine any issues you might have and where to make adjustments. This test is crucial because it will help you in the long run.

10. Full Implementation and Continuous Improvement

You can implement your barcode system in your manufacturing plant if everything goes right. But keep an eye on it and gather helpful information. Do regular checks and improve the system to make your manufacturing process more efficient over time.

Benefits of Implementing Barcode Systems in Manufacturing

There are a lot of benefits to implementing barcode systems in manufacturing, but we will be looking at the big three.

Better Tracking of Inventory

Barcodes help prevent mistakes when keeping track of how much stock you have. By scanning barcodes, you can quickly and accurately update your inventory, avoiding errors when typing in information.

Easier Tracking and Seeing Products

Barcodes make it simpler to follow a product’s journey from production to delivery. Just by scanning the barcode, you can closely monitor where the product is, ensuring good quality control.

Faster and Smoother Manufacturing

Barcodes speed up manufacturing because they automate the process of recording information. This means things get done more quickly and accurately, reducing the time it takes to do tasks and lowering the chances of mistakes.

Challenges of Implementing Barcode Systems in Manufacturing

There are benefits to implementing a barcode system in your manufacturing process, but there are also problems. We will examine the three most common challenges to installing a barcode system in a manufacturing plant.

Initial Setup Costs

Setting up a barcode system requires an initial investment in barcode scanners, printers, and software. These costs can sometimes be a challenge for businesses, especially smaller ones. However, it’s important to consider the long-term benefits of efficiency and accuracy.

Employee Training

Teaching your team how to use barcode scanners and software takes time. Everyone needs to be comfortable using the new technology. Good training is critical to getting the most out of the barcode system.

Integration With Existing Systems

Making the barcode system work with your current systems can be complicated. It might not fit perfectly, and adjustments may be needed. Planning carefully and working together are essential to make sure everything runs smoothly.


From tracking your inventory from start to finish to making your manufacturing process smoother, there are a lot of uses for those black-and-white lines (barcodes). But you need to know which type to use. Implementing barcode systems in the manufacturing process isn’t easy. There are a lot of steps you need to follow and challenges you need to overcome. But the end result will ensure you produce and deliver your products faster and without any mistakes than your competitors.


Q. How do barcode systems improve inventory accuracy?

Barcode systems provide real-time tracking, minimizing errors in inventory management.

Q. What are the initial challenges in adopting barcode systems?

Initial challenges include setup costs, employee training, and integration with existing systems.

Q. Can barcode systems be customized for specific manufacturing needs?

Yes, barcode systems can be tailored to meet the unique requirements of each manufacturing setting.

Q. Are there sustainable practices in barcode technology?

Yes, manufacturers are increasingly adopting eco-friendly options, including recycling and reducing the environmental impact of barcode systems.

Q. What is the future of barcode technology in manufacturing?

The future includes trends such as IoT integration and machine learning applications, reshaping manufacturing processes for greater efficiency.