Features/Benefits Provided: Reduced inventory Eliminated 3rd shift build personnel Increased plant efficiency Allowed just-in-sequence product build operation Provided pedigree tracking

This automotive parts supplier's location provides cooling modules to its site's largest automotive manufacturing customer. The cooling modules (1 of 10 possible types) are pre-assembled units that are delivered in the exact build sequence to the vehicle assembly plant.

Aided with simulation modeling, the supplier's solution led to a unique answer. The design was a right-first-time optimized assembly line for small lots. It included pedigree tracking and line scheduling software to support the 2-shift make, 3-shift ship just-in-sequence (JIS) operation. Pedigree tracking allows recall of all quality data recorded at each assembly line workstation during product build. The supplier also provided a 2-aisle, unit-load automated storage and retrieval system (AS/RS) and systems integration.

The automotive manufacturer sends a live line broadcast to the automotive parts supplier's facility, requesting a particular module type and stating the vehicle identification number (VIN) of the vehicle it is to be installed in. The storage and retrieval machine (SRM) responds by pulling the correct module type and placing it on a delivery conveyor to the shipping pick point. While en route, a label containing the VIN is applied to each module, identifying it for installation in a unique vehicle.

Two aisles of the supplier's SRMs are used to sequence up to 2,500 modules between assembly and shipping. The AS/RS consists of double deep racks to increase density. All modules are uniquely identified and retrieved on a first-in/first-out (FIFO) basis.

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