Background
Decoma Sybex, part of the $24bn Magna Corporation, is a supplier of exterior vehicle appearance systems to some of the world’s leading car and vehicle manufacturers. With factories around the world, Decoma still manufactures exterior trim in the UK for car manufacturers such as BMW.
The Challenge
The automobile market is one of the most competitive in the world. Automotive manufactures were the first adopters of the principles of Lean manufacture – the elimination of unnecessary wastage in the manufacturing process. Decoma, as a supplier to leading automotive companies, needs to continually improve the quality of the service it provides.
Decoma supplies exterior trim systems ready for assembly. The trim systems are assembled straight on to the car on the production line from stacks in cages supplied by Decoma. The delivery of the wrong part, or parts in the wrong order, can seriously impact the efficiency of the production line.
Decoma were looking for a way to reduce errors in its production process and hence avoid falling short of the stringent quality standards demanded by its customers.
The Solution
Decoma approached Modcomp to help design a shop floor system to reduce production errors. The solution devised by Decoma and implemented by Modcomp was based on a bar coding system using hand held computers from Motorola.
Being a Microsoft Gold Partner, Modcomp elected to build the application using Microsoft software. This would ensure that the system was robust, cost effective and future proofed.
The database system is based on Microsoft’s SQL Server database while the application logic uses the .Net Compact Framework 2.0 and runs on the Motorola hand held computers under Microsoft’s Windows Mobile 5.0 operating system. The client software is written using win forms and web forms so can be accessed from lap tops and PCs as well as the Motorola hand held computers.
In Operation
Now in operation the Modcomp system allows workers on the shop floor to tag parts using Odette standard bar code labels printed by the Zebra Z4M Bar Code labelling printer. The system’s database keeps track of the parts and ensures that when they are packed ready for shipment to Decoma’s customer, they are packed in the correct order. Since the system went live, Decoma has not had one exception report from its customers, which in turn has meant that Decoma has met its quality targets and not been financially penalised by the supplier. In effect the system has paid for itself in real terms and in terms of improving the quality of customer service.
Conclusion
After the system went live, Modcomp further enhanced the system by developing a reporting suite which provided the shift and senior managers at Decoma with metrics relating to performance on the shop floor. Details could be provided down to operative level as each operator had a unique log-in name. The reports added additional benefit to Decoma. Modcomp continues to support the system ensuring that Modcomp too maintains its reputation for excellent customer service.