Supply In Line Sequencing system devised

A vital link in the supply of parts and sub-assemblies to lineside at General Motors' European flexi-plant in Ellesmere Port, Cheshire is the sequenced delivery of parts to the lines.

Linpac Materials Handling is providing a vital link in the supply of parts and sub-assemblies to lineside at General Motors' European flexi-plant in Ellesmere Port, Cheshire.

Manufacture of the new Vectra alongside the popular Astra model, presented Vauxhall with unique logistics challenges.

This development heralded the move to an innovative logistics process - "Supply In Line Sequencing" (SILS), which gave Vauxhall the flexibility to assemble its two car models from the same line according to market demand.

Previously all parts for immediate assembly had been located adjacent to the assembly line and picked by the operative as and when required.

SILS took the decision of picking the correct parts for each particular car model away from the line operative, replacing it with a system which ensures all required parts are delivered to match each particular model as it arrives on line.

The task of coordinating the logistics for this process was contracted out to market leading transport and logistics provider Ryder, who contacted customised packaging solutions specialists LINPAC Materials Handling.

Linpac were duly tasked with creating a storage solution, which could accommodate a wide and diverse variety of automotive components and present them in sequence to a lineside environment where space is very much at a premium.

A system of Lineside Modules (LSM's) was devised by Linpac, each module being custom-built to house and protect a particular component and designed to economise on space usage as much as possible.

The scale of the project - comprising some 70 different LSM designs - warranted in-depth involvement from LINPAC Materials Handling, and Ryder's requirement that this part of the project be fully integrated into its tender plan, led to the secondment of a dedicated Linpac Automotive Account Manager to the project for a six month period.

The first task was to review the huge range of components to be handled.

Extremes in size and shape, ranging from compressor units and pipes which could not be compacted, through to fragile parts such as painted panels, steering wheels and headlights, presented a whole range of challenges, each demanding a bespoke, yet economically and logistically feasible solution.

Working together with Linpac's Manchester-based fabrication and vacuum forming plant, a prototype was developed for each LSM.

These prototypes were then presented to Vauxhall's production and quality staff in order that trials and feedback could be received before full-scale production commenced.

The LSM's comprised a variety of units, most incorporating matrixes of 'pigeon-holes' sized precisely to accommodate specific parts.

Materials used included lightweight Corex - a moisture proof, damage and decomposition resistant plastic 'sandwich' which offers flexibility with excellent product protection.

Many of the LSM's were housed within specially constructed metal frames which could be handled by forklift trucks or on wheeled dollies for quick and easy transportation to lineside.

Following modification and fine-tuning, a full sample unit of each module was constructed in time for Vauxhall's production pilot, prior to the SILS project's official launch in March 2002.

Despite the strict timescales laid down and the fact that Linpac effectively started with a blank sheet of paper, the project deadline was achieved on time.

Coordinating packaging for 70 different automotive parts was a challenging task - even more so when taking into account the fact that some of the parts were not physically available, and drawings and verbal dimensions had to be relied upon to formulate their LSMs.

The success of the project is testament to good teamwork, project management, planning and packaging innovation.

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