Sequenced delivery Custom Solutions

Mass customization combined with the need for lean inventory is having a significant impact on the manufacturing industry. Manufacturing OEMs and their suppliers are moving from manufacturing large batches of identical components to having components and assemblies produced and delivered in the order the customers demand them (i.e. in sequence). This requires the delivery of custom configured items in the order/sequence the OEM requires, to the point of application in the production line. The name given to this requirement is sometimes called, Sequence Suppliers (SS), Sequenced In-Line Supply (SILS), In-Line Vehicle Sequencing (ILVS), or Just in Sequence (JIS). Independent of what you call it, the objective is a demand driven, build to order, manufacturing process (i.e. Mass Customization). An effective sequencing solution includes:

• The Ability to Accept and Respond to the EDI Call-Off, Broadcast or Pull-Signal

  Most OEM’s broadcast a pull-signal to every sequence supplier in phase with the Takt time. This signal contains the order identification number and the configuration specification of that particular order. Suppliers internal and external then have a limited time to get the right items in the right sequence to the right point of application on the production line. This pull-signal/broadcast is the triggering event to generate an accurate bill of materials and appropriate work instructions for each workstation.

• Reverse sequencing for transport loading

  When items are required in sequence, many times they are delivered on trucks. In these cases the sequence of production may be the reverse of what will be deliver, because the first item loaded is actually the last item off the truck.

• Error Proofing Capability

  A supplier found responsible for stopping the OEM’s production line, can be liable for lost production. Consequently, error proofing consists of a set of methods to minimize errors. This includes designing product and equipment to ensure items can only be assembled correctly, automatic scanning and RFID identification to check for the right parts, automatic equipment and quality measurements to insure a repeatable process.

• Traceability and Visibility

  For some items such as air bags, engines, fuel tanks and tires, traceability is a government mandate. For quality analysis and product recall campaigns, traceability lowers overall cost and helps increase customer satisfaction. In these cases an effective interface to an After Sales and Service application system is required.