A Tier-1 automotive supplier, responsible for just-in-sequence deliveries to a major OEM, was managing highly time-sensitive and accuracy-dependent production operations. With thousands of components being picked, packed, and shipped daily, the client needed a solution that could ensure seamless communication, eliminate manual errors, and provide full process visibility from OEM broadcast (EDI) – to final shipment using a robust automotive parts sequencing software.
Business Challenges
To address these critical challenges, the company sought an end-to-end automotive manufacturing and logistic software solution that could improve operational efficiency while reducing human errors.
Operational challenges
The client faced operational challenges in OEM broadcast validations and lacked real-time monitoring, making in-line vehicle sequencing broadcast inefficient and error-prone.
Manual Picking Process
The picking process, managed manually, was prone to human errors due to the absence of guided systems.
Label and document printing
Label and document printing was inconsistent, causing shipment delays and mismatches.
Lack of Live Visibility
Lack of real-time visibility made it hard to track progress, while limited traceability caused audit issues.
Isolated Function Operations
Functions operated in isolation, with little integration between hardware or software systems.
OEM Broadcast Monitoring
The solution featured a live OEM Broadcast module that provided real-time visibility with timestamps at each stage — received, acknowledged, and processed — ensuring full transparency and control for the OEM assembly plant.
Pick & Pack Using Modern Handheld Devices (Zebra TC21 & TC22)
Zebra TC21 handheld devices with built-in barcode scanners enabled precise part scanning during picking and packing. Real-time validation ensured only correct components progressed through the process.
Lighting System Integration
To reduce human error during part picking, an automated part sequencing software was integrated with a WebSocket-based lighting system using SignalR and Raspberry Pi controllers was deployed at key stations. This setup triggered real-time projector lights to visually guide operators to the correct aisle or part bin, streamlining the process and significantly improving picking speed and accuracy.
Automated Printing Services
Python-based microservices automated label and document printing across stations, ensuring documentation integrity. They also enabled intelligent printer swapping to prevent downtime and delivery delays.
Display Stations
Large Display Stations showed real-time, work-area-specific data like shift activity, progress, and alerts. This improved visibility, decision-making, and coordination across pick, pack, and sequencing operations.
Shipping Station
The Shipping Station module tracked BOLs, load statuses, and shipment timings with clear visual indicators. It also enabled document handling and real-time performance monitoring through shipment ratio graphs.
Global Search
The Global Search tool let decision-makers quickly find data using Load ID, BOL, or sequence numbers. It supported detailed views, reprinting, exports, and role-based access—crucial for audits and quality checks.
User Management Module
The User Module let admins create and assign roles like User, Admin, or Supervisor with specific access rights. This ensured secure, role-based control over platform features and maintained accountability.
Solutions Provided
The answer came in the form of parts sequencing, a comprehensive digital sequencing platform built specifically to handle the complex needs of high-volume, real-time manufacturing and shipping environments.
Another critical component was the deployment of Large Display Stations across the shop floor. These displays were customized to show real-time data relevant to each work area. For example, in the pick and pack zones, operators and supervisors could see shift-level activity, progress indicators, and alerts – all live and synchronized across stations. These real-time visualizations also made in-line vehicle sequencing more visible and manageable for supervisors, improving decision-making and reducing the risk of delays.
The Shipping Station module played a vital role in managing the final step of the process. It tracked Bills of Lading (BOLs), shipment timings, and load statuses. Visual indicators on the screen helped the team identify which part sequencing Container had been loaded and which were still pending. Additionally, the station supported the downloading and reposting of shipping documents (BOL), while real-time shipment ratio graphs enabled performance monitoring at a glance.
BMVSI Add Ons To The Sequencing Software
Powerful extension that drive Efficiency, Minimize Downtime, and Maximize Output
Introducing Intelligent Notifications: The Call Bell System
One of the most critical innovations in the system was the Notification / Call Bell system.
This wasn’t just a button. It is an intelligent issue reporting with an auto-escalation solution. Whenever an operator faced an issue — be it a stuck printer, a barcode scanner fault, or a process-related query — they could activate the Call Bell directly from their station device.
Instantly, the system sent out email and SMS notifications to the assigned maintainers for the current shift.
- These maintainers were given exactly 8 minutes to acknowledge the issue, tracked by the system.
- If the issue wasn’t acknowledged within that window, or if it remained unresolved beyond the next 10 minutes of acknowledgment, the system automatically escalated the alert to a person with higher authority, ensuring that no issue was left unresolved.
This escalation logic brought unprecedented responsiveness and accountability to the floor. It empowered operators to report problems confidently and ensured timely support from the right personnel. Ultimately, it minimized idle time, reduced frustration, and prevented minor issues from snowballing into major operational delays.
Fail-Safe Data Architecture: Replication & Backup
To protect operational data and ensure uninterrupted system availability, two key data mechanisms were implemented:
1. Real-Time Database Replication
To further enhance operational reliability, the platform implemented real-time database replication between primary and secondary servers. This ensured continuous data consistency and high availability, protecting the system against unexpected failures or downtime.
2. Shift-Wise Auto Backup Mechanism
To further enhance operational reliability, the platform implemented real-time database replication between primary and secondary servers. This ensured continuous data consistency and high availability, protecting the system against unexpected failures or downtime.
The core technologies and framework leveraged to build and deliver the solution for part sequencing.
Result
The implementation of Sequencing led to measurable improvements across the board.
Barcode Validation
Prior to the system, picking accuracy hovered around 88%. After the solution was deployed, that number rose sharply to over 99.5%, thanks to barcode validation and lighting guidance.
Python Microservices
Label printing errors and delays were virtually eliminated, with the Python-based services ensuring that documents were printed precisely and instantly.
OEM Broadcast
The time taken to acknowledge broadcasts from the OEM dropped from several minutes to near-instant processing.
Automated Documentation
Shipment documentation became highly reliable, reducing the need for manual corrections or rework.
Real-Time Dashboard
Supervisors who once had to rely on verbal updates now had a real-time dashboard to monitor shift activity, making proactive management possible.
Call Bell System
The Notification / Call Bell system quickly became essential to operations. Operators could request help without leaving their stations, and with built-in escalation, no issue went unnoticed or unresolved.
Global Search
Audit and compliance checks, which once required combing through paper logs and scattered data, could now be completed with just a few clicks. With Global Search, every shipment, part, or label was traceable and responsive, transforming OEM assembly plant performance standards.
Impact Table
The following table quantifies the significant benefits and successful outcomes generated by our work on this case study.
Sequencing transformed our operations. With automated validations, guided lighting, and instant print services, we’ve reduced errors, improved throughput, and made life easier for operators and supervisors alike.
The sequencing case highlights what’s possible when digital innovation meets real-world operational challenges. By bringing together real-time software, connected hardware, automated printing, and intelligent workflows, the platform has created a seamless, end-to-end system that boosts productivity, reduces human error, and supports data-driven decision-making.
For any manufacturing or logistics environment seeking scalability and precision, Sequencing is a benchmark in operational excellence. By enabling just-in-sequence accuracy and supporting in line vehicle sequencing with automation, the platform exemplifies next-gen automotive parts sequencing software.
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