Why I Tried This
In our SMT line, we faced a simple but critical problem: some PCBs are only laser-marked on the bottom side.
Our MES, however, requires laser markings on both sides for full traceability across stations.
We explored a proper fix — installing bottom-side scanners — but the investment was steep (RM4,800 per line) and still under management review.
So I proposed something different: a Mirror Aid setup that might allow our top-side scanner to read the barcode by reflection.
What I Built
The concept was straightforward:
- A mirror mounted underneath the conveyor
- A phone holder to support and adjust mirror angle
- A top-mounted scanner attempting to read the bottom-marked code through reflection
Goal: avoid flipping the PCB, avoid new hardware, and preserve traceability during the waiting period.
What Happened
The setup technically worked, but with real-world limitations:
| ✅ What Worked | ⚠️ What Didn’t |
|---|---|
| Simple to set up | Lighting reflections caused scan issues |
| Kept production flow moving | Only ~66% scan success rate |
| Zero cost beyond materials | Required careful manual positioning |
| Supported traceability gap | Too fragile for scale-up use |
What I Learned
- The idea was right, but the execution had gaps.
- I underestimated lighting and reflection complexity, especially under factory conditions.
- Yet, the experiment was still worth doing — because it moved the conversation forward and gave us real data to assess feasibility.
Even a partial failure can be a step forward in MES improvement work.
What’s Next
- Re-evaluate scanner investment based on volume and ROI
- Refine the setup with better materials (Maybe a concave mirror?)
- Document this in WikiMES as a case of field experimentation
Cost Breakdown
| Item | Price (RM) |
|---|---|
| Phone Holder/Each | 13.90 |
| Mirror (7×10.8 cm) | 3.48 |
| Mirror (11×16.5 cm) | 9.38 |
| Super Glue | 3.50 |
| Total | ~RM30 |
🔗 Related Posts
Final Thought
Not every idea needs to succeed to be valuable.
The Mirror Aid didn’t solve our traceability challenge completely — but it gave us momentum, insight, and proof that we don’t need to wait for perfect conditions to take action.
Lastly, I want to show my preparation…
