Grupo Antolin, a major manufacturer of automotive components based in Spain, supplies headliners to Ford - overhead "ceilings" which incorporate various electronics, lighting and safety features such as airbags. A couple of years ago, Ford required Grupo Antolin to convert its facility to an in-line vehicle sequencing system, in which parts are built, assembled and shipped in the same order as they are assembled at the Ford plant. To keep Ford's business, Antolin had to increase its annual production by 500,000 headliners and accommodate at least 80 new component styles. Antolin decided to transition to a demand flow-based manufacturing process, fully automated with robotics and pick-to-light bins controlled by a single data source. Microscan fixed-position bar code scanners were selected for accurate data capture.

The assembly process begins when Ford sends an EDI data file telling Antolin how many finished units need to be assembled and shipped during the next six days. Once the headliner substrate has been removed from its mould, it is labelled with an initial bar code used for inventory tracking, scanned and hung in a style rack. The scheduling program prompts the operator to print another label with the finished unit bar codes in the order which corresponds to the sequential assembly order at the Ford plant. The substrates are then placed on an assembly fixture, where the automated work in progress begins with data capture. The Microscan scanner reads the bar codes on the label and then transmits the data to the host where the data is compared with the finished bill of material file and an instruction sent to the robot which glue pattern to use. At the same time a digital signal illuminates a "pick-to-light" bin signalling the appropriate wiring harness to be installed. The reduction in inventory is automatically registered. The data collection and work in progress tracking is repeated at each station of the assembly process, with the entire operation controlled by software and wireless communication.

In addition to enabling Grupo Antolin to meet Ford's requirements, the system has brought other benefits, as the operational efficiencies achieved mean that the company has been able to cut production from three shifts to two and a half. Grupo Antolin is so pleased with the system that it is making plans to replicate this production process in its 15 plants worldwide.

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