MAPP Trail - Traceability Module

Track every part/product through the manufacturing process, raw materials entry to finished product and everything in between.

Traceability will track and trace every part and process of the manufacturing to immediately identify the batch and order to avoid COPQ (Cost of Poor Quality). Upstream and downstream process will be tracked in a very smart and effective way of finding the errors/mistake in the product and manufacturing line. Inspection results, assembly details and time spent at each station are recorded.

By searching the downstream flow, you can discover which finished products have been produced based on specific starting components and incoming materials. By searching upstream, you can identify the starting components and materials used for the selected finished products, batches or orders.

Processing units can be uniquely identified using a tracking number (such as the product or sequence number). This identifying number will then point to a record with all of the acquired information, such as the performed quality inspections, process and operational data, involved work centres, time stamps, starting components and materials, tools used and so on. The various available evaluation and filter settings make it possible to draw conclusions about the units potentially affected by defective components.

BENEFITS

Increased customer satisfaction.
Better visibility of WIP inventory on the shop floor.
4M ( Man , Machine, Material and Method) traceability.
Timely recall of products when quality defects are recognized.
Traceability can be extended to customer or supplier operations.
Automated data acquisition using Direct Part Marking (DPM) technology.

CASE STUDIES

Business Challenge

The customer was incurring a higher cost of poor quality. In case of recalls or customer complaints, there was no way of tracing back the precise reason or time, in the absence of which a surgical solution could not be implemented to address the complaint.

Solution Offered

Implemented MAPP trail module which tracked the parts as they came into the factory, went through each process, and eventually dispatched. Direct part marking (DPM) was used to identify and keep track of each part.

Outcomes Achieved

Implementation of traceability software-enabled timely recall of defective parts, once an issue was identified. Customer satisfaction improved.