Implementation with complex IT requirements in 6 months

For a European automobile manufacturer, moviniti handles the pre-assembly of five modules as well as the just-in-time and sequenced supply of wiring harnesses. For the sequencing and pre-assembly of five modules, a total of seven interfaces, a new pre-assembly function, and a special logic were required, all of which were successfully implemented within six months.

⚙️ Assembly and JIS, sequence, 🚘 Automotive

Sequence areas

Average picks/month

75000

Storage space

9500

The challenge

Replacement of a legacy system for inventory management, sequencing of wiring harnesses, pre-assembly of five modules, and just-in-time loading of wiring harnesses and modules. The main challenge during implementation was the automotive manufacturer’s requirement that the wiring harness to be delivered had to be determined by the system based on specific vehicle attributes. Another challenge was the non-digital interface for receiving call-off data.

Replacement of a legacy system for the entire logistics process: goods receipt, storage, replenishment, sequencing, pre-assembly followed by sequencing, loading
No interface for digital transmission of call-off data (manual process)
Transmission of a list of vehicle attributes instead of transmitting the wiring harness to be delivered
Complex logic to determine the optimal wiring harness for JIS delivery
Integration with the wiring harness supplier’s system for exchanging various data
Requirement for early warning notification in case of missing stock based on the OEM’s forecast planning
Short lead time of 50 minutes from receipt of call-offs to loading into the plant

The solution

All three functional modules—moviniti warehouse, sequence, and assembly—were implemented at the site.

Solution for the missing interface for the digital transmission of call-off data
- Together with the OEM, an interface was designed and implemented for the digital transmission of call-off data
Development of a special tool outside the standard moviniti functionality for determining the most cost-effective cable harness
Functions of moviniti warehouse
- Basic functions in addition to the replenishment process and loading
- Receipt of a digital delivery note and reconciliation after delivery of the cable harnesses
- Feedback after completion of incoming goods inspection via an interface
- Replenishment of small load carriers and full pallets to fixed picking locations
- Automatic loading planning for direct delivery of all provided sequence racks
Functions of moviniti sequence
- Sequencing in sequence racks with compartments in sequence order and route-optimized (for MAIN and BODY)
- Additional quality assurance after sequencing in route-optimized order to ensure 100% accuracy
- Printing of customer-specific sequence labels
Functions of moviniti assembly
- Digital process guidance per workstation in the manual assembly of modules (tailgates, charge air coolers, center consoles, headliners)
- Automatic creation of variants based on the transmitted bill of materials via the interface

Implementation with complex IT requirements in 6 months

The challenge

The solution

The result

Seven digital interfaces for sequence retrieval, forecasts, assembly data, and shipping successfully implemented.

The assembly function was implemented as a product extension within six months.

Sequencing of assemblies and cable harnesses is route-optimized and performed in reverse order.

Customer-specific sequence labels successfully integrated.

Implementation of a custom solution for determining the appropriate wiring harness for each vehicle variant.

Significant improvement in user guidance compared to the previous system.

Implementation with complex IT requirements in 6 months

The challenge

The solution

The result

Seven digital interfaces for sequence retrieval, forecasts, assembly data, and shipping successfully implemented.

The assembly function was implemented as a product extension within six months.

Sequencing of assemblies and cable harnesses is route-optimized and performed in reverse order.

Customer-specific sequence labels successfully integrated.

Implementation of a custom solution for determining the appropriate wiring harness for each vehicle variant.

Significant improvement in user guidance compared to the previous system.

Logistics know-how