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Success story

Automotive Tier 1 Supplier

Automated bumper tracking: optimized WIP, no overruns.

A leading Tier 1 Supplier, producing automotive bumpers for a major car manufacturer, faced complexities in managing production overruns and ensuring precise traceability throughout their manufacturing process. By implementing automotive bumper production RFID, they gained real-time visibility into Work-in-Progress (WIP), optimizing flow and stock management.

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Challenge

Managing Overruns and Complex Variants

Bumper production involves molding machines that, once running, cannot be stopped precisely at required quantities. This often results in overproduction (e.g., needing 1,000 but producing 1,300), creating excess stock. The supplier needed to accurately identify each unique bumper variant (distinguished by model, front/back, sensor holes, etc.) and precisely track its production details—including production time, raw material used, and the specific car model it was made for. This granular traceability had to be maintained through harsh manufacturing environments, including high-temperature painting lines, and then efficiently manage the resulting excess inventory.

Automotive bumper manufacturing with bumpers on skid on their way to paintline RFID tagged

You can't stop production when the molding machine has material. So, you're not producing 1000 bumpers, you are producing 1300. And it is a problem.

Benefits

Precise Production Traceability

Automated WIP Visibility

Resilience to Harsh Environments

Optimized Overrun Management

Outcome

The automotive bumper production RFID solution provided the Tier 1 Supplier with full, item-level traceability for every bumper throughout its entire production cycle, even through high-temperature processes like painting. This enabled precise management of production overruns, ensuring accurate stock control and allowing excess inventory to be effectively utilized for subsequent orders.

Solution

RFID-Enabled End-to-End Bumper Tracking

The Tier 1 Supplier implemented an automotive bumper production RFID solution, providing detailed tracking from molding through to finished goods:

  • RFID Tagging at Molding: An RFID tag is affixed to each bumper immediately after it exits the molding machine. This tag is encoded with critical data: production time, raw material used in that shift, and the specific car model for which the bumper is intended.
  • Tracking Through Harsh Processes: These RFID-tagged bumpers are then placed on skids (up to 8 bumpers per skid) and tracked through subsequent production steps, including high-temperature painting lines. The RFID tags are specifically designed to endure and remain readable through these demanding conditions.
  • Real-time Production Step Registration: At every stage, the RFID system registers completion of each production step for individual bumpers, capturing what has been done and automatically updating their status.
  • Excess Inventory Management: After painting, finished bumpers are tracked to a mezzanine floor stock area. This allows for precise management and delivery directly from this surplus inventory.

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