Traceability journey in goods manufacturing Processes
Traceability in Manufacturing Industry
Client Summary :
Our Client is a leading manufacturer of advanced automotive components. With a strong focus on innovation and quality, the company supplies engine and filtration systems to major OEMs, adhering to the highest standards of good manufacturing practices.
Industry :
- Global leader in automotive components.
Challenges :
- Seamless Zebra Printer Integration:
Faced issues with ZPL-based network printing. Solved by creating a middleware with ZPL templates and preview features—reducing label errors and wastage. - Dynamic QR Code Generation:
Needed unique, context-aware QR codes at each stage. Built a flexible QR generator with genealogy links, real-time metadata, and optimized scan reliability. - Configurable Process Interlocks:
Managed complex workflows with mandatory and optional stages by designing a skippable process interlock engine mapped to product types and rework routes. - Pallet Splitting & Sub-Level Traceability:
Addressed traceability gaps caused by pallet splits using a hierarchical parent-child pallet system with retained history and reportable splits. - Hybrid Traceability Through Harsh Processes:
Handled QR code damage during heat treatment by implementing pallet-level tracking and switching to product-level post-process with continuity maintained via checkpoints.
Project Success Factors :
- Batch traceability of raw materials helps quickly pinpoint the batch involved during client quality-related escalations.
- Enables to gain deep visibility into each process stage—like quenching, hardening, tempering, and forging—by identifying whether the material stayed within or exceeded critical threshold levels, thus ensuring quality control and process
transparency. - The project’s success was driven by its intelligent traceability architecture that ensured end-to-end product genealogy even through destructive processes. A dynamic, context-aware QR ecosystem enabled real-time, error-free labeling with adaptive interlocks. Enhanced accuracy through OK/Not OK status logging and detailed rejection tracking improved accountability. Comprehensive reporting empowered informed, data-driven decisions.
Customer Feedback :
“Instron Technologies has transformed our manufacturing visibility with their robust traceability solution. From raw material intake to finished goods dispatch, every step is now trackable in real time. The hybrid traceability model they implemented—pallet-
level before heat treatment and product-level afterward—was perfectly aligned with our operational needs.”