Astra Logistics
"Exacta orchestrates our order entry, production planning and error proofing systems to ensure that we ship the correct products 100% of the time. It performs data analysis and management to ensure all tire and wheel assemblies shipped by Astra meet or exceed the customer's expectations."
- Bruce Muir, PE, Vice President of Astra Logistics
System Summary
DaimlerChrysler Corporation was transforming the company's 3.4 million square foot Newark Assembly Plant into a Flexible Manufacturing Facility (FMF). Astra Logistics, a tier one automotive supplier located in Delaware, was awarded the contract to build and deliver tire and wheel assemblies to the Chrysler Plant in Newark on a just-in-time basis.
Business Challenge
- Chrysler needed to receive a wider range of wheel and tire styles that could be updated in real time.
- Astra needed to minimize the amount of floor space leased and the amount of purchased parts inventory managed to reduce operating costs.
- Cycle times had to be quick, yields needed to improve to reduce rework and scrap, and plant labor hours needed to be reduced.
- Machine life had to be extended to minimize capital spending.
- Product history data had to be captured and archived in a cost-effective and efficient manner.
Key Technologies
- ASAP PictureViewâ„¢ Pick-to-Display
- Warehouse Control Software
- Steeplechase conveyor controls
- One 2-level pick module
- 3-lane pick module conveyors utilizing high speed Bi-directional diverts (22 cases per minute)
- Ermanco narrow belt sorter for pack Mettler-Toledo in motion check weighing systems
- Hytrol pre-sort Shoe Sorter Accusort line scanners and omni-directional scanner
- Transnorm gravity chutes
- Blue Arc Engineering empty carton flow racks
Results
- ASAP integrated its Manufacturing Execution Software, Exacta LINK software with a wide variety of enterprise applications and shop-floor process control systems.
- ASAP's Exacta LINK Manufacturing Execution Software provided access to real-time Chrysler production data.
- Astra Logistic experienced a reduction in manufacturing cycle times, as well as a reduction in WIP inventories and their associated capital requirements with the new system.
- Visibility improved across the operation with Exacta Console Digital Dashboard.
- Paper processes were eliminated and relevant reporting and analytics were provided.
Photos and Media
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