MERLIN for Automotive: From Lot-Level Visibility to True Part Genealogy
In the automotive sector, where safety, accountability, and rapid containment define competitiveness, digital traceability has shifted from “nice-to-have” to a foundational capability. We position ourself squarely in this need: pairing MERLIN Tempus for machine and operator activity capture with partner technologies like JobQ Manager to deliver end‑to‑end, part‑level genealogy across complex, multi‑operation lines.
Why Traceability Matters Now
For Tier‑1 and Tier‑2 suppliers, OEM expectations and IATF-16949 compliance demand the ability to follow each component—from raw material lots, through forming and welding, to final assembly and shipment—so issues can be isolated and contained in minutes, not hours or days. In practice, this looks like a seat‑frame manufacturer linking every finished part back to its material heat, every intermediate operation, inspection, and container, enabling precise root‑cause isolation and rapid response to customer inquiries or field concerns.
Our Solution Blueprint
Our approach is built on a layered architecture that integrates enterprise planning with shop‑floor execution and device‑level data capture:
- Enterprise (ERP) Layer: The ERP remains the system of record for customer, part master, BOM, routing, and work orders, sharing this master data with MERLIN and JobQ through simple batch interfaces (e.g., CSV, DB views).
- Manufacturing Execution & Monitoring: MERLIN Tempus imports jobs, parts, operations, machines, operators, and material lots; it captures machine states, job start/stop, production counts, scrap, downtime, and shift context. Operators identify the active lot and job at each station via barcode, ensuring each cycle is tagged correctly.
- Flow-Line Orchestration (JobQ Manager): In cells with parallel parts and multiple concurrent operations, JobQ Manager orchestrates job queues and WIP tokens, routing parts between stations and robots, enforcing scan discipline, and driving serialized label printing through custom HMIs—while connecting via SQL/Web APIs to ERP, MERLIN, printers, and device gateways.
- Device & Control Layer: PLCs, robot controllers, weld controllers, vision systems, and gauges stream operation events (OK/NG, parameters) that JobQ/MERLIN attach to the correct part or WIP token. Label printers, scanners, and RFID readers complete the identity loop at each touchpoint.
- Traceability & Quality Data (Genealogy DB): A central database stores material lots, work orders, operations, machines, stations, operators, part serials/WIP IDs, process parameters, inspections, non‑conformances, containers, and shipments—supporting both backward trace (part → lot → certs) and forward trace (lot → parts → containers → shipments).
- Analytics & Reporting: Dashboards provide lot genealogy, forward trace, SPC charts, defect Pareto, downtime‑quality relationships, and RCA/TOC views—turning captured events into management insight.
This architecture creates a reliable “digital thread” from coil to customer, with MERLIN Tempus at the core and JobQ Manager ensuring the flow lines never lose the identity of the part in process.
How It Works on the Floor
The operational sequence is straightforward and disciplined:
- ERP → MERLIN/JobQ: Nightly and on‑demand updates share part masters, routings, BOMs, and work orders; lot creation rules are defined per part/operation (e.g., per coil).
- Receiving: Material is received and material lot records are created in ERP; lot labels are printed with 2D codes and synchronized to MERLIN/JobQ.
- Execution: Operators log in to MERLIN, scan the job and lot, and run parts; MERLIN associates the lot with work order, operation, machine, operator, and shift. For complex lines, JobQ maintains the WIP token per part/carrier and validates scans at each station.
- Process Data Capture: PLCs, welders, robots, and vision systems send operation events to JobQ/MERLIN, powered by our comprehensive connectivity tools; these are attached to the correct part serial or WIP token, lot, and operation, including weld parameters and inspection results.
- Final Assembly & Packout: A unique Part Serial is assigned at the final station and linked to material lots, all prior operations, inspections, container IDs, and shipment records.
- Shipment & ASN: The ERP manages shipments and ASNs; container and serial lists flow back into the genealogy database for recall/trace readiness.
IATF‑Aligned Governance, Built In
The solution framework aligns with IATF-16949:2016 requirements for traceability (8.5.2), control of production (8.5.1), nonconformance handling (8.7), and documentation. It defines responsibilities (plant/quality/production/IT), standard procedures from lot creation to final serialization and packout, mock‑recall drills at least annually, and retention policies (e.g., program lifetime + 15 years), all supported by digital records rather than paper.
Implementation as a Measurable DMAIC Program
Management teams can roll out this capability using a Six Sigma DMAIC project structure:
- Define: Move from batch‑level, paper‑based records to digital genealogy; target retrieval of full part history in ≤ 5 minutes for any serialized component within 9 months.
- Measure: Baseline current traceability completeness (% of parts with full genealogy), time to identify impacted parts for a suspect lot, and inspection record coverage.
- Analyze: Use Fishbone/5‑Whys and TOC tools to quantify root causes (missing scan points, integration gaps, operator behavior, uncontrolled rework paths).
- Improve: Pilot MERLIN + JobQ + device integration on one product family/line, introduce new scan points and labels (lot, WIP token, part serial, container), then iterate to a standard solution pattern.
- Control: Standardize SOPs and work instructions; train operators; audit traceability daily/weekly; error‑proof production starts if lot or job isn’t scanned; and hand over ownership to plant/quality and IT for sustained performance.
Ready to get started?
Contact our sales team for more information, to request a quote, or to schedule a live demonstration.
