Beyond the Barcode: How Real Time Traceability Exposes Volatile Assembly Efficiency

Abstract

This research targets the introduction of traceability in master production scheduling (MPS) and focuses on the two-wheeler assembly line. Some issues, such as demand fluctuations, production capacity constraints, expensive emergency shipments, and worker ineffectiveness, continue to be present during production planning. To combat these problems, a traceability system, which includes PLC, HMI, sensors, QR code printing, and SQL Server, integrated to provide real-time shift-based production data of K1 EBR ABS model for all the three shifts. The planned vs. the actual data along with rework and scrap data show significant shift-dependent outcomes (first shift achieved 40% good parts (4 ok, 4 rework and 2 scrap from 10 planned); second shift 64%; third shift 75%; with no scrap). Weekly production efficiency fluctuated between 10% and 70% with no patterns. The research shows that traceability allows for the identification of root causes of quality losses, as well as loss of quality and efficiency. The main contributions are an applied traceability model and evidence for shift-dependent quality variation in automotive assembly.