CASE STUDY

In late 2004 then Daimler-Chrysler awarded Toledo Molding and Die, Inc., a Toledo, Ohio based Tier 1 automotive supplier, the 2007 JK Platform contract to provide Instrument Panels, Center Consoles and Door Panels to the Toledo South Assembly Plant for the Jeep Wrangler.

The Challenge

Toledo Molding and Die, Inc. (TMD) was required to begin shipping S1 parts by late February 2006.  In addition to selecting a contractor to design and build the instrument panel assembly line, TMD also needed to select and deploy a sequencing solution that included Manufacturing Execution System (MES) capabilities. This was needed to ensure that customer error-proofing requirements were met for the instrument panels as well as to manage the pack/ship-to-sequence center console and door panel requirements.

Daimler-Chrysler (Chrysler) instrument panel error-proofing requirements included:

• Pick-to-light key component selection with subsequent scan validation.
• Collection and storage of torque controller data including angle, Newton-meters of pressure, and Pass/Fail results.
• Storage of Electrical/Continuity Tester results.
• Proven back-up processes for everything from receipt of broadcast to automated population of the trailer number on the shipping manifest.  This was done via a PLC link to the truck docking station.
• Rebuild and repair processes for safety-critical components.

Additionally, the chosen solution needed the capability to create, store, and archive detailed serial# genealogy of all key component parts against the vehicle VIN#.  The same was true for safety critical torque data and Electrical Tester results.

The Solution

The TMD launch management team selected New Technologies, Inc., located in Grand Blanc, MI, to design and build the instrument panel assembly line.  TMD selected Insequence Corporation, located in Smyrna, TN, to provide a Sequencing solution for the center consoles and door panels.  TMD and New Technologies, Inc. jointly selected Insequence to provide Sequencing and MES for the instrument panel line to manage the sequence-to-manufacture and error-proofing requirements of the instrument panel line.

According to the TMD launch team the key drivers in selecting Insequence Corporation were their deep automotive focus and expertise, a solid product, and a proven track record of success with several other Chrysler suppliers.

The Results

Key TMD and New Technologies personnel were quickly identified and began working with the Insequence SPD Pro implementation team.  Project milestone dates were established and known roadblocks were identified. Monthly meetings were held with the Chrysler JK Launch Team.  The end result was that the S1 and other launch commitments were met and TMD was compliant with all error-proofing and vehicle VIN# genealogy mandates.

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