Omni-ID & Detroit Diesel
AIM 2015 RFID Case Study Competition Participant
The Business and Technical Challenge
Detroit produces a new engine every 2.5 minutes with a total plan of about 55,000 engines per year in the current build out. In Detroit’s HDE Engine Assembly Area they are producing 170 engines per shift. This has the plant working at capacity, in continuous overtime mode, thus driving the operations team to seek ways to find where efficiencies could be added to the production process. One of the areas identified was parts replenishment.
Like many manufacturers Detroit was using a decades old paper-based system to manage their parts replenishment cycle, in this case paper Kanban tickets and orange signal flags. When the production operator reached the replenishment point they raised the orange flag on the cart signaling the Tugger Operator to pick up the cart and transport it to the bulk warehouse to be replenished. Upon arrival at the bulk warehouse the Forklift Operator assigned to the zone replenished the material needed on the cart. After the pick was completed the Forklift Operator updated DIBS (ERP system) manually using a local terminal.
Seeking a solution to improve their material handling practices and collect metrics that allow them to optimize the replenishment process Detroit found the answer with Omni-ID’s ProVIEW Solution. This system incorporates Omni-ID’s View 3 tag, a rugged e-paper tag whose button technology allows the Detroit production operator to communicate with backend systems to manage parts replenishment between the warehouse and production floor and ProVIEW software.
After identifying Omni-ID’s Call Button Solution as the replacement for the prior system, the Detroit management team met with Omni-ID’s implementation team to work through the operational procedures required to use the technology in the most beneficial way possible.