JIT Auto Parts. Zero Line Stoppages
Tier 1 manufacturer in pure just-in-time operation with no safety stock. Two-hour cycle with 25+ suppliers. Any verification failure stops the line.
The Challenge
Tier 1 manufacturer in pure just-in-time operation with no safety stock. Two-hour cycle with 25+ suppliers. Any verification failure stops the line.
Zero-buffer JIT. Returnable assets: racks, containers, packaging traced over the full cycle. Any verification failure stops the production line.
The Solution
- 25+ suppliers integrating active and passive RFID tagging at origin
- 3 high-velocity portals verifying complete and incomplete shipments
- Real-time ERP integration closing the production cycle
- Shipment verification (complete or incomplete) resolved at the portal, not on the line.
- Returnable assets (racks, containers, packaging) traced over the full cycle.
Context
Tier 1 manufacturer in pure just-in-time operation with no safety stock. Two-hour inventory cycle with 25+ suppliers delivering in synchronized windows. Any verification failure stops the production line.
Approach
Diagnostic mapped delivery points and characterized each flow. Bounded Deployment integrated critical suppliers over one portal. Full Project extended to the 25+ suppliers with high-velocity portals.
Architecture
Passive RFID tagging on product + active tagging on returnable racks · high-velocity RFID portals at receiving · real-time order verification · ERP integration closing the production cycle · zero manual handling, full traceability.
Implications
In pure JIT, RFID traceability is a condition for line continuity. The cost of implementing it amortizes against a single avoided stoppage.
Let's schedule your Diagnóstico
Send us your details and we will quickly contact you.
