Optimizing the material distribution method for automotive electronic switch production: A rigid and flexible approach

Abstract

The lifecycle of automotive electronic switches is relatively short. The products exhibit a high level of customization. The assembly production demonstrates characteristics of high variety in small batch sizes and frequent production changeovers. Traditional delivery methods often result in issues such as excessive line-side inventory, residual material accumulation, and material management disorder. In this article, a reverse planning approach is adopted to logically analyze from the material demand side to the supply side. By integrating the concepts of push and pull production control, a just-in-time delivery sequencing model is designed. Furthermore, the model was validated based on production data from Company A. The aim is to reduce line-side inventory, improve delivery accuracy, shift from ensuring material supply to efficient supply, and enhance inventory turnover. The purpose of improvement is to achieve a 20% reduction in floor space occupied by the assembly workshop at the same production level, decrease line-side inventory (including raw materials, work-in-progress, and finished goods) by 30%, increase inventory turnover by 20%, reduce the working hours required for logistics personnel by 30%, and improve the accuracy of material deployment (including quantity and part number) from 92% to 99%.