Webasto Roof Systems is a leading manufacturer of roof and temperature management systems for automobile manufacturers. Its sunroofs are found in millions of cars around the world. In the automotive industry, it is extremely important that parts are labeled correctly prior to reaching a manufacturer's assembly line. For Webasto, if its sunroofs are mislabeled, a black sunroof could end up in a white car. To ensure this does not occur, Webasto labels its sunroofs so that the right sequence of roofs matches an assembly line order. Proper sequencing assures that the right sunroof is installed in the assigned vehicle. The incorrect sequencing of one sunroof can cause assembly lines to shut down for hours at a time, which translates into lost time, money and penalties.
Under the new system from Intermec and ToolWorx, only one auditor is needed for the quality assurance check which takes place at the end of the production line. A number of automated tests are performed on the sunroof to ensure that it meets all quality standards. After successful testing, an approval bar code label is automatically printed and applied to the sunroof. Once a rack is filled, all of the sunroofs are scanned in position order into the Intermec PM4i printer to validate their part number, color, and sequence within the rack. If the validation is successful for all modules, the rack label is printed allowing the sunroofs to be staged for shipment.
"The Intermec PM4i printer has an integrated processor, complete with operating system and programming language that enables the development of a fully independent solution," said Ray Silvius, business analyst for Webasto. "Because the system is self contained, production is not interrupted if our network or ERP system becomes unavailable. Ultimately, this component, combined with its industrial construction, reputation for durability and previous experience with Intermec is why we chose the PM4i over competing products."
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