In the world of manufacturing, where supply chains are global and complex, maintaining product quality is crucial. This is especially pertinent when demand spikes lead to material shortages, forcing manufacturers to source materials from new, sometimes less-established suppliers. Such situations can expose manufacturers to risks associated with substandard parts.
Rockwell Automation, a global manufacturer with a diverse product range and extensive manufacturing plants, recently encountered such a challenge. The company faced a surge in demand for component parts for an electronic assembly, compelling it to procure materials from an external source. This posed significant risks to their operations, customers, and broader supply network.
Digital transformation and integrated operational technology and IT systems played a key role in addressing this challenge. Rockwell Automation’s unified production data across all facilities allowed the team to swiftly identify and address quality issues. This comprehensive system enabled them to determine which specific products were affected by the substandard parts, allowing for targeted reworks rather than broad-sweeping recalls. The incident highlighted the immense value of traceability in manufacturing. With detailed tracking and documentation of products from raw materials to finished goods, Rockwell Automation was able to isolate the problem within its distribution centers and manufacturing operations. This minimized operational disruptions and contained the issue effectively, preventing it from reaching their customer base.
Looking forward, Rockwell Automation aims to achieve complete end-to-end traceability, tracing serial numbers from suppliers to finished products. This goal involves building a connected supply chain that can track product origins from all distribution channels and validate quality before parts enter the manufacturing ecosystem. Such a traceability system not only ensures quality control but also provides a competitive edge. It allows manufacturers to maintain high standards throughout the supply chain, ensuring that the integrity of products is maintained at every stage. This operational intelligence is crucial in today’s global and interconnected manufacturing landscape, where maintaining product quality and customer trust is paramount.
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