Problem Statement

The automobile manufacturer receives multiple sub-parts from various vendors and assembles them into the final product on the shop floor. However, due to the lack of a proper traceability system, they are unable to track sub-components used in each product or identify which products were shipped to specific customers.

This gap in product and sub-part traceability has resulted in increased customer rejections, difficulty in root-cause analysis, and challenges in quality control and supplier accountability.

Architecture

Solution

  • Apeiron addresses this challenge by implementing a complete end-to-end traceability system using AVEVA software integrated with barcode scanners and printers across RM stores and production lines.
  • Barcode generated for each lot/part received from vendors and added to inventory
  • Quality team approval captured before material issue
  • FIFO-based material issue from RM stores to production
  • Each assembly station equipped with a barcode scanner
  • Operator scans lot barcode before production start
  • System verifies:
    • FIFO compliance
    • Quality approval
  • Production allowed only after validation
  • Final barcode generated at the end of the line and applied to finished product
  • Final product barcode mapped with all sub-part lot barcodes

Benefits

  • Complete forward & backward traceability.
  • Elimination of wrong-lot usage & quality escapes.
  • Faster root-cause analysis for customer rejections.
  • Higher accountability for vendors and assembly operations.