For automotive parts and final assembly, One-MOM combines station level error proofing, material replenishment and end to end traceability in one closed loop, so mixed-model lines no longer depend on veteran intuition.
Connects torque guns · electric drivers · ANDON · vision · PLC · on-premise deployment
One station handles an ever growing number of configurations. Part recognition and paper work instructions let wrong or missing parts slip to the next station, or to the customer.
Many similar parts share one station with wide configuration differences. Manual part number recognition cannot interlock errors at the station.
Rework and line stop account for 60%+ of quality lossTightening data stays local to the controller and is never bound to the vehicle VIN, so audits rely on manual record hunting.
Critical characteristic data completeness below 70%Line side shortages coexist with excess stock. Delivery takt and line takt are disconnected and kitting status is invisible.
Line side inventory turnover 5.8 daysAndon calls happen by voice, supervisor response is unrecorded, and downtime lacks owner attribution and closure tracking.
Average exception response 14 minutesThese problems share one root cause: the station lacks real-time judgement, hard interlock and automatic record keeping.
From device signal capture to traceability reporting, One-MOM closes the loop on one platform. Data is never re-handled, and judgement results act directly on station release.
Torque guns, electric drivers, vision, RFID, ANDON and PLC signals are unified; station level data is reported within 200 ms.
Vehicle configuration auto-matches routing and configured BOM; torque, angle, turn count and kitting status are judged against rules in real time.
Nonconforming units are not released and do not flow forward. ANDON escalates by tier to supervisors, process and maintenance; picking is guided by light instead of memory.
VIN or serial number is the thread joining man, machine, material, method and environment; a bidirectional traceability report is generated in one minute.
Splitting sensing from judgement, or execution from traceability, is the classic cause of broken data chains in assembly. One-MOM runs all four stages on one data model, so rule changes reach the station immediately without re-integrating each system.
Assembly quality risk concentrates in tightening, kitting and traceability. One-MOM delivers deployable station level capability for each.
Hard interlock Process parameters feed torque guns and drivers directly. Torque, angle and turn count are judged live; out-of-tolerance locks the station and raises a rework order automatically.
JIT / JIS Line takt drives material pull. Picking tasks are generated per configuration and guided by light instead of memory, with shortage risk warned in advance.
One item one code Serial number is the thread joining material batches, operators, equipment parameters and inspection records, in both directions.
Control points, trigger conditions and system actions are configuration, so shift and variant changes no longer depend on verbal handover.
| Station | Control point | Trigger | System action |
|---|---|---|---|
| Interior station | Wrong configuration part | Scanned variant does not match the physical part number | Lock station and push correct part number with image |
| Chassis tightening | Torque out of tolerance | Torque or angle outside the tolerance band | Alarm at station, raise rework order and quarantine |
| Fluid filling | Fill volume deviation | Fill deviation above 2% | Suspend filling and notify the process engineer |
| End of line test | Missed inspection item | Inspection items incomplete or not passed | Block certificate print, vehicle cannot be stored |
| SPS kitting area | Kitting risk | Kitting rate below current takt demand | Warn 30 minutes ahead and chase replenishment |
| Rework station | Rework closure | Defect not closed or re-inspection failed | Vehicle cannot proceed to the next stage |
Process engineers configure every control point on the low-code platform; new variants or tolerance changes need no custom development.
Line status, critical characteristic judgements and exception events are linked on one screen, so supervisors stop switching between systems.
| Line / Section | Status | Shift output | First pass yield |
|---|---|---|---|
| Line A final assembly | Running | 386 units | 99.4% |
| Line B final assembly | Running | 352 units | 98.9% |
| Interior section | Shortage warn | 341 units | 99.1% |
| Chassis section | Running | 372 units | 99.6% |
| End of line test | Running | 358 units | 99.3% |
Typical before and after indicators for assembly projects. Actual results vary with line maturity and deployment scope.
Full judgement of critical characteristics raises end of line pass rate
Hard interlock replaces manual recognition, errors do not escape
Tiered ANDON with timeout escalation, previously 14 minutes
Pull replenishment replaces guesswork, previously 5.8 days
Indicators are typical customer statistics six months after go-live and depend on a site assessment.
Book an on-site diagnostic for your line. We will deliver a deployable station control point list and a migration path.