Federal Mogul and Ariane: towards a « Just-in-Time » picking management
Federal Mogul is a renowned American automotive supplier and its Belgian site in Aubange is specialized in making wipers. The site is now considered as a world reference for the group in research and development (8% of human resources). With an area of 26.000 m2, a turnover around 50 millions euros and a production capacity of hundreds of millions components, the Belgian factory evolves since 1978 despite the increasingly competitive market. If like many companies it wasn’t spared by difficult choices over the past few years, it is thanks to strategic and reflected choices that it was able to allow its maintenance and constant evolution on the market.
Today exclusively dedicated to parts production whose assembly is partially performed in Hungary, it is by whole pallets that Federal Mogul Aubange was shipping these different components at regular intervals.
At the request of these assembly sites to carry out “just in time” orders to significantly reduce inventory, a box or tray picking solution became necessary instead of the existing pallet picking.
Because this solution was dedicated to field operators whose workload increased as well, its prerequisites were usability, ergonomics and intuitiveness first.
UP trace has been selected for its barcode inventory management solution : “The existence of Ariane by UP trace Middleware is a key time-saving factor in compliance with the schedule required by the group and its modularity, an obvious advantage. This is also the long-lasting recognized and appreciated collaboration with an experienced team that made us decide” explains Joël Collard, Team Leader AS400 EMEA for Federal Mogul MotorParts.
ARIANE by UP trace is composed of a set of Windows services installed on a central server and of clients on mobile wireless terminals.
Drawing centralized information (pick lists, articles, …) in the management system AS/400 of Federal Mogul, Ariane makes them available to field operators to do the following operations :
- Managing and securing the produced parts picking
- Packaging management before expedition
- Labels printing for final customers (Ariane Print+NiceLabel module)
These operations are performed using robust and suitable industrial equipment, chosen for its high reliability:
- PSION Work About Pro (WAP) G3 and G4 handheld terminals for orders Pickers
- PSION 8515 embarked terminals on forklifts for stock Operators
- Zebra ZM600 for customer labels printing before shipping
Approved by the Global LEAN Manger for its friendliness, the UP trace application fully responded to Federal Mogul's expectations: in terms of investment, period of implementation and success of on-site testings. Joël Collard confirms his choice today: “UP trace shipping management solution has streamlined the implementation of our Hungarian partner's requirements, while ensuring effectiveness and reliability. The responsiveness and availability of UP trace team were major assets during the test period and for all adjustments requested”.