Published on: December 22, 2024 / Update from: December 22, 2024 - Author: Konrad Wolfenstein
The Data Matrix Code (DMC) in Industry 4.0 and 5.0 - The technical industry is undergoing profound change - Image: Xpert.Digital
The role of the GS1 Data Matrix Code in the technical industry
The growing requirements of Industry 4.0 and 5.0
The technical industry is undergoing profound change, which is largely driven by innovations such as the GS1 Data Matrix Code (DMC). In times of Industry 4.0 and the emerging concept of Industry 5.0, the demands on companies are continually increasing as there is a growing demand for highly digitalized, secure and reliable processes. Products should not only be clearly identifiable, but ideally be able to be integrated into complex IT systems to enable extensive data evaluations, intelligent automation and new business models. The GS1 Data Matrix Code makes an indispensable contribution because it opens up numerous opportunities for companies - regardless of their size or industry focus - to secure and strengthen their own competitiveness in the long term.
The GS1 Data Matrix Code as the basis for digital transformation
“The use of the GS1 Data Matrix Code in the technical industry plays a crucial role in ensuring competitiveness in the context of digital twins, IoT, Industry 4.0 and 5.0.” This statement illustrates the enormous influence that the DMC has now gained explains why more and more companies are daring to adapt their processes accordingly. The Data Matrix Code is not just used to label products. Rather, the basis is created for the consistent digitalization and networking of all information required for production, delivery, use and maintenance.
Compact data storage in the smallest space
A key factor in the popularity of the GS1 Data Matrix Code is its format, which can store a wealth of information in a small space. For complicated assemblies or very small parts such as screws or electronic components, all relevant data can be accommodated without major problems. In the technical industry, it is common for a single product to consist of countless individual components. If each of these components is clearly labeled and traceable, it can be quickly determined when and where it was manufactured, which batch or batch was used and, for example, when the next maintenance appointment is due. Sensor data can also be accessed and assigned in a higher-level system at any time by simply reading the code and linking the data together.
Robustness and reliability under difficult conditions
An important property of the data matrix code is that it is robust and can still be read correctly even if it is slightly damaged. This is particularly important in environments where there is contamination, abrasion or other stress. In the metalworking industry or when used in outdoor areas, it is therefore a clear advantage to have a code that works reliably even under less than ideal conditions. If components are exposed to hot temperatures, moisture or chemical substances, scratches or other wear can quickly occur. Thanks to special error correction mechanisms, the GS1 Data Matrix Code ensures that reading remains possible in most cases. This means that components do not have to be laboriously re-labeled or replaced, which both saves costs and streamlines processes.
Permanent marking through Direct Part Marking (DPM)
Another relevant point is the possibility of Direct Part Marking (DPM). The code is permanently applied to the component itself, for example by engraving, laser marking or needle embossing. In this way, the marking is retained throughout the product's entire lifespan. This is particularly important when it comes to components that are exposed to high loads or have to withstand long periods of use. Such solutions increase transparency and traceability throughout the entire product life cycle, which is of considerable importance not only for production and logistics, but also for maintenance and complaint management.
Standards and efficiency in networked production
However, the ability to reliably record and store data is only one side of the coin. In order for this process to be embedded in a consistently networked context, open and established standards are needed. “The GS1 Data Matrix Code is characterized by space efficiency, versatility, robustness and direct marking.” These features have contributed to the DMC becoming a quasi-standard in many technical areas. By using the GS1 system, the data is clearly assigned and can be clearly identified worldwide without any overlaps. For this purpose, the GTIN (Global Trade Item Number) or a serial number is stored in the code to uniquely identify each product or component.
Digital twins: integration and optimization
The DMC becomes particularly valuable when it is integrated into more comprehensive concepts, such as the digital twin. A digital twin is a virtual image of a real product that contains all relevant information about the properties, condition and history of this product. This data can, for example, be stored in the cloud and networked with other systems. “The unique identification by the DMC forms the basis for the creation of digital twins of products and components.” Companies that provide their components with an individual data matrix code have the decisive advantage that they can access current information at any time. This information can in turn be incorporated into analyzes in order, for example, to optimize maintenance intervals or to be able to predict when a component is likely to need to be replaced (predictive maintenance).
Digitization through DataMatrix Code
The DataMatrix Code serves as a clear and unique product identifier that lays the foundation for the development of a digital supply chain. At Schaeffler, each rolling bearing is marked with an individual DMC , which enables complete traceability from the manufacturer to the operator.
Creation of digital twins
By using the DMC, companies can create digital twins of their products. These virtual representations combine data from different sources:
- Construction data: CAD models and performance parameters
- Production data: measured values and manufacturing information
- Logistics data: location and delivery status of the products
These comprehensive data models enable customers to map and simulate their machines completely digitally.
Advantages of integration
Integrating products into digital twins offers several benefits:
- Optimized maintenance: Maintenance costs can be reduced and the reliability of systems can be increased.
- Increased efficiency: Customers can quickly evaluate different configurations and optimize performance.
- Improved traceability: The entire life cycle of a product can be tracked, which is particularly useful for maintenance and component replacement.
- Data-based decisions: Extensive data enables well-founded decisions in development, production and operation.
GS1 standards and IoT
The use of GS1 standards such as the DataMatrix Code is crucial for implementing IoT solutions:
- Uniform identification: GS1 identification numbers enable objects, machines and people to be clearly identified.
- Interoperability: GS1 standards act as a common language for data exchange between different systems and companies.
- Linking to digital twins: The GS1 Digital Link allows physical objects to be connected to their digital representations.
By using these standards, companies like Schaeffler can seamlessly integrate their products into digital ecosystems and thus benefit from the advantages of Industry 4.0.
Seamless integration into IoT systems
A look at IoT applications reveals another relevant aspect. The Internet of Things (IoT) refers to networked devices and machines that can independently exchange data or trigger actions. If a product is integrated into such an IoT system via a data matrix code, information about this product can be recorded or updated automatically. For example, a machine in production can recognize which component is currently being installed and adapt the manufacturing process accordingly. “The code enables the seamless integration of products into the Internet of Things by acting as an interface between the physical and digital worlds.” This is referred to as “cyber-physical systems”, which form a central basis of Industry 4.0 and 5.0.
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Advantages of the GS1 Data Matrix Code in the supply chain
The advantage in the supply chain, i.e. in the entire supply chain, is just as important. Products can be scanned with the DMC at every stage of the value chain to determine where they are currently located, when they will arrive and which processing steps have already taken place. In industries with particularly high security requirements, such as the automotive industry or the medical sector, the code makes a significant contribution to counterfeit protection.
“Particularly in the automotive spare parts market, the GS1 Data Matrix is used as a MAPP (Manufacturers Against Product Piracy) code to protect against counterfeiting.” In this way, companies can protect their customers by ensuring that only authentic components are put into circulation. At the same time, it has a positive effect on the brand image if products can be proven to be authentic.
Schaeffler as a successful example of the GS1 Data Matrix Code
A clear example of the successful use of the GS1 Data Matrix Code is the company Schaeffler, which is internationally known particularly in the field of rolling bearings. Schaeffler relies on GS1 standards to clearly and permanently label its products.
“By labeling the bearing components with a unique DMC, Schaeffler creates the prerequisites for creating a digital twin for its railway products.” This shows the importance the concept of the digital twin now has: Schaeffler is thus implementing a flexible, scalable and holistic business model of Industry 4.0. In addition, the labeling significantly simplifies the exchange of information between component suppliers, vehicle manufacturers and operators. If sensors and telemetry systems are integrated into the bearings, you can see in real time whether a component is still in perfect condition or whether it is showing signs of wear.
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Industry 5.0: Synergy between people and machines
This approach, which merges product labeling, digital twin, IoT and cloud-based data processing, is not only forward-looking, but also important for the vision of Industry 5.0. While Industry 4.0 is primarily aimed at networking and automating production, Industry 5.0 puts people more at the center again. It's about humans and machines complementing each other and supporting each other. People take on creative, planning or controlling tasks, while machines carry out the routine work.
The GS1 Data Matrix Code acts as a “bridge” between the two worlds. Thanks to clear labeling and transparent data management, people – for example service technicians or plant operators – can interact efficiently with highly automated systems without losing track of the complex processes.
Predictive maintenance through integration of sensor data
“Predictive maintenance: Linking DMC data with sensor data allows for predictive maintenance and optimization of operational processes.” This principle shows the enormous potential that arises from the widespread use of such technologies.
For example, planned maintenance can be scheduled precisely if sensor data suggests that certain parts will soon reach their tolerance limits. This allows unplanned downtimes to be minimized and production utilization to be maximized. In addition, real-time information can often be used to determine in advance whether process optimization or product adjustments make sense, before expensive failures occur.
Potential for companies through GS1 Data Matrix Code
Overall, the use of the GS1 Data Matrix Code in conjunction with Digital Twins, IoT and the principles of Industry 4.0 and 5.0 results in numerous advantages for companies in a wide range of industries. This starts with better traceability and anti-counterfeiting and extends to the development of new business models. For example, service providers can offer to continuously monitor products based on extensive analyzes and only bill the customer for actual use - a so-called pay-per-use model. This flexibility and ability to adapt to changing market conditions proves to be essential in order to stay ahead of the competition.
Importance for large and small companies
Large manufacturers like Schaeffler demonstrate that these standards have been tested in practice and applied successfully. But it is also advisable for small and medium-sized companies to deal with the topic of GS1 Data Matrix Code at an early stage. These companies are often integrated as suppliers in global supply chains that work according to uniform standards. Anyone who cannot keep up runs the risk of losing important orders or being excluded from certain markets.
However, thanks to increasing standardization and the availability of professional marking solutions, it is no longer rocket science to mark your own products with a data matrix code and set up the corresponding processes.
Flexibility and innovation through standardization
In its pursuit of digitalization and competitiveness, the technical industry cannot do without a tool like the GS1 Data Matrix Code. With a compact, robust and versatile labeling solution, comprehensive information is available to everyone involved in the value chain - from the manufacturer to the logistics provider to maintenance personnel.
This information can in turn be integrated into intelligent systems to realize more efficient processes, better quality assurance and innovative business models. “By using the GS1 Data Matrix Code in conjunction with digital twins and IoT technologies, companies in the technical industry can sustainably secure their competitiveness and optimally position themselves for the challenges of Industry 4.0 and 5.0.”
The Schaeffler example particularly impressively highlights how a well thought-out and consistently applied marking concept can usher in a new level of digitalization and at the same time open up new value creation potential.
The future belongs to companies that recognize these opportunities and make full use of them - and the GS1 Data Matrix Code is more than just a small code on a component. It is the key to a new level of networked value creation and the engine for further advancing industrialization, at the center of which people, machines and data operate in a highly efficient and intelligent interaction.
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