Magna International Inc.- QAD MFG/PRO and Real Time Data Collection

QAD MFG/PRO and Real Time Data Collection helps Magna/Norplas achieve GM Supplier of the Year award in 2001

Magna International Inc., one of the most diversified automotive suppliers in the world, designs, develops and manufactures automotive systems, assemblies, modules and components. Magna also engineers and assembles complete vehicles, primarily for sale to original equipment manufacturers (OEM’s) of cars and light trucks in North America, Europe, Mexico, South America and Asia.

THE CHALLENGE

Magna’s Norplas Industries Inc. facility, in Toledo, Ohio, supplies injection molded bumper systems to numerous OEM’s. Norplas utilizes QAD MFG/PRO to plan and execute its manufacturing and delivery requirements to its customers. Each of these customers places unique requirements on Norplas in terms of product quality and 100% labeling and shipment accuracy. The proliferation of styles and colors on the product make it impossible to guarantee labeling and shipping accuracy with standard systems and human intervention/inspection.

THE PARTNERSHIP

Norplas teamed with Radley Corporation, A QAD Alliance Partner and provider of automated data collection solutions for QAD MFG/PRO, to automate the processes needed to meet the demanding requirements of their customers. Norplas wanted to first implement Radley's data collection solution in their assembly and sequencing department. The objective initially was to resolve outstanding labeling issues that Norplas was unable to achieve with previous attempts at automation.

THE SOLUTION

The process involves scanning a bar code on every part as it is loaded into shipping racks, with Radley’s system providing the confirmation that every part loaded into the rack is the same part number, and that no part was scanned twice. Once the standard pack has been reached (determined via real time integration to QAD), a confirmation step takes place to generate rack labels (Norplas generates and scans over 9,000 part and 800 rack labels per day). The final step in this labeling process is to verify that the rack label matches the parts on the rack to ensure the label was not inadvertently placed on the wrong rack. Once confirmed, this automatically triggers the back-flush transaction into QAD and this rack is now available to be shipped to the customer.

Utilizing Radley for shipping enables this rack labeling integrity to be protected. Any re-labeling that is required prior to shipping includes a verification step, and all racks that are scanned for shipments must have been properly verified. The solution also ensures that the correct shipping labels are generated at the appropriate time and that the right racks, get on the right truck, in the right quantity, at the right time. About 2500 customer specific shipping labels are printed daily.

THE RESULTS

The Radley solution has proven extremely effective in eliminating Norplas' label accuracy concerns, and has created a real-time production reporting system that is effectively integrated into all manufacturing activities. Labeling issues have essentially been eliminated, shipping accuracy has effectively been 100%, and labor efficiency has been improved. Norplas continues to build on the robust Radley solution for new challenges with new customers and products.

David Steel, Norplas’ Production Control and Logistics Manager, had this to say, “Utilizing the Radley solution, and other measures, Norplas has significantly improved our customer ratings, culminating in the presentation of the GM Supplier of the Year award in 2001. GM indicated to us that the technology utilized in Norplas' manufacturing processes is unparalleled.”

Norplas is currently implementing a Warehouse Management System and the Radley system has provided the necessary foundation to move forward with warehousing efficiencies. The warehouse has 100% accurately labeled racks and parts entering the warehouse, with instant integration between the WMS and Radley.

Radley’s solution collects data from barcodes, RFID, scales, PLC’s and other manufacturing systems for real time integration into QAD MFG/PRO.