How a component manufacturer gained the history tracking of each part at its plants in Poland and Mexico with traceability system
The traceability system integrated data from production, quality control, and SAP (an ERP system). As a result, the serial number now links to the product’s history, and any defective unit is flagged before the next operation.
- Industry: automotive components manufacturing
- Locations: plants in Poland and Mexico
- Scope: automated and manual workstations, machines, SAP, reporting
- Objective: To track the production process and quality of each unit
The serial number did not lead to the product’s history
Before implementation, the products were labeled, but their production data was not entered into a shared system. After scanning the serial number, it was impossible to determine what components the item was made of, what processes it had undergone, or what inspection results it had received.
The complaint lacked the information needed to quickly trace the production process. It was more difficult to identify the source of the nonconformity and determine which products needed to be inspected.
Our client needed a record of the product’s genealogy and the quality history of each unit. The same identification and control procedures were to apply at the plants in Poland and Mexico.
The system stops the defective product before the next operation
We have implemented an MES-class traceability system for both automated and manual workstations. As a result, the serial number is now linked to the components used, the operator, the workstation, the sequence of operations, the process parameters, and the quality status.
Before starting the next step, the system checks whether the previous operation was performed and completed with an “OK” status. It also verifies the component’s validity and prevents the reuse of the same code.
An item marked as NOK is blocked and cannot proceed further. Production is halted for any item that has not passed the previous inspection. The final label is printed only after the entire process has been successfully verified.
Production data is sent to SAP
The system retrieves information about production orders from SAP and transmits data on the number of units produced. This reduces the need for manual data entry between production and the ERP system.
We have implemented an integration for both plants with the aim of maintaining common standards for identification, control, and reporting.
Product history is retained for 25 years, so the quality department can access product data even long after production has ended.
Implementation in Poland and Mexico
We began by conducting a process audit and mapping the workstations. The team reviewed the flow of components, quality control points, labeling procedures, and the scope of communication with the machines and SAP.
The system was first launched at the Polish facility and then in Mexico. The project required collaboration with machine integrators operating in both locations. Coordination was hampered by distance, the time difference, and differing project deadlines on the suppliers’ side, but all these obstacles were successfully overcome.
A common standard for communicating with the machines made it easier to implement the solution at the second plant. Before the integration, we also established a division of responsibilities among explitia, the client, and the machine suppliers.
How has the implementation changed the client’s work?
Product history available by serial number
The quality department can check the components, process parameters, sequence of operations, and inspection results assigned to a specific unit.
Recall of a Defective Product
A part with NOK status, an incorrect component, duplicate code, or a missing operation does not proceed to the next station.
More Efficient Handling of Complaints
The data makes it possible to trace the production process more quickly and identify the products that need to be inspected with greater accuracy.
Less manual data entry
Data on orders and completed production is exchanged between the traceability system and SAP.
The same rules apply at both facilities
The plants in Poland and Mexico use a common system for identification, quality control, and reporting.
The first step is a process map
If you want to achieve similar results at your facility, a traceability system may be the best solution for you, and we at Explitia would be happy to help you implement it.
We’ll start with an initial consultation, a workshop, and a pre-implementation audit. We’ll review the machinery, the product flow, the labeling process, and the data exchanged with the ERP system.
Based on this, we will help you determine the scope of integration, the division of responsibilities, and the sequence of tasks.
If you’d like to learn more about traceability or implementation, please contact us, and we’ll be happy to explain the process, as well as the integration of machines and data that need to be connected.
Let's talk how traceability can address the needs of your production
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