Production Line WIP Tracking Implementation for Electric Vehicle Assembly Plant
Real-time work-in-progress tracking system deployment across 4 assembly lines for a leading EV manufacturer, enabling precise production monitoring and quality control.
Client Overview
A rapidly growing electric vehicle manufacturer needed to implement a comprehensive work-in-progress tracking system across their new assembly facility. With production ramping up to meet increasing demand, they required real-time visibility into component flow, assembly progress, and quality checkpoints.
The Challenge
The client faced significant challenges in tracking work-in-progress across their complex assembly process, leading to production delays and quality issues.
Limited Visibility
No real-time tracking of components and subassemblies moving through the production line, making it difficult to identify bottlenecks or locate specific units.
Quality Control Gaps
Manual quality checkpoint documentation led to inconsistent records and difficulty tracing defects back to specific production stages or component batches.
Inventory Discrepancies
Frequent mismatches between system records and actual component locations on the production floor, resulting in production delays and excess safety stock.
Production Metrics
Lack of accurate cycle time data and production efficiency metrics made it challenging to optimize processes and identify improvement opportunities.
Our Solution
We deployed a comprehensive RFID-based WIP tracking system integrated with the client's manufacturing execution system (MES).
RFID Infrastructure
Installed 48 RFID readers at strategic checkpoints across all 4 assembly lines, with automated data capture at each production stage.
- Fixed portal readers at line entry/exit
- Workstation-mounted readers at quality gates
- Mobile handheld readers for exception handling
Real-Time Dashboard
Developed custom dashboards providing live visibility into production status, component locations, and quality metrics.
- Line-by-line production status
- Component traceability and genealogy
- Automated alerts for exceptions
MES Integration
Seamlessly integrated tracking data with existing MES and ERP systems for unified production management.
- Bi-directional data synchronization
- Automated work order updates
- Quality data integration
Implementation Approach
Results & Impact
The WIP tracking implementation delivered significant improvements in production efficiency, quality control, and inventory accuracy.
Key Achievements
"The WIP tracking system has transformed our production operations. We now have complete visibility into every vehicle moving through our assembly lines, enabling us to optimize flow, improve quality, and scale production efficiently. The implementation was seamless and the results exceeded our expectations."
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