20% reduction in process times for sequencing 12 part families

The replacement of a legacy system with moviniti in the production-synchronous supply of an OEM for 12 product families reduced process times in upstream processes (putaway, replenishment) as well as in sequencing by 20%.

sequence, 📍 OEM Munich, 🚘 Automotive

Sequence areas

Picks per month

150000

Warehouse specialists

The challenge

The goal of the project was to replace a legacy system for all processes at the logistics site for just-in-sequence supply of seat covers.

Replacement of a legacy system for all processes from goods receipt through sequencing, including replenishment, up to just-in-time loading
Testing of moviniti in parallel operation with the legacy system using different replenishment logics (FIFO could not be strictly represented in the legacy system)
Implementation of a process to secure the replenishment process for order gaps (missing stock during sequencing)
Transfer of surplus stock from the legacy system and execution of a stocktaking to correct inventory levels
Extremely short time frame of 2 days between the last scan in the legacy system and the start with moviniti
Change for employees after many years of working with the previous system

The solution

Implementation of moviniti sequence
- 4 interfaces (sequence retrievals, speedometer, ASN goods issue, picking request for replenishments)
- Goods receipt with 1D and 2D VDA labels
- Replenishment to fixed picking locations considering FIFO and index changes
- Sequencing in reverse order
- JIS and JIT loading including digital advance shipping notice

Extremely short timeframe of 2 days between the last scan in the legacy system and the start with moviniti
- Parallel testing on site with logistics managers
- Preparation of migration of inventory & orders from the legacy system
- Storing all delivered goods to ensure an empty goods receiving area
- Building up maximum lead time for production
Change for employees after many years of system use
- Continuous training
- Close involvement of team leaders & site management
- On-site support after go-live from moviniti experts on both shifts

The result

Reduction of process costs by 20% in replenishment and sequencing

Successful use of moviniti from 2019 to today

Additional features and process steps were implemented within a few weeks after go-live.

Strict adherence to FIFO in the replenishment process

Digital process for detecting and tracking missing inventory during sequencing

Early detection of implausible data through the introduction of additional warning messages when receiving call-off data

Testimonial

Location

Manager