Case Study 04
Lean Store/VLM Integration with Biometric Access & BOM-Driven Outbound
Overview
A global manufacturer of high-precision industrial components operating multiple warehouses supporting lean production. The firm required a robust solution for inventory automation, FIFO compliance, and traceable operator interactions — all while enhancing space utilization and reducing manual dependency.
Problem Statement
- Lack of Secure Machine Access: Operators could access machines without accountability, increasing error risks.
- Manual Stock Picking: Outbound materials were picked based on operator judgment, often violating BOM requirements.
- Inconsistent FIFO Enforcement: Expired or older parts were occasionally skipped.
- Labor-Intensive Counting: Frequent physical verification consumed hours.
- Limited Traceability: No linkage between operators and inventory activities.
- Manual Error Handling: Faults during operations were hard to trace or analyze.
Objectives
- Automate inventory handling using Lean Store and Vertical Lift Module (VLM).
- Secure machine access via biometric login (fingerprint, RFID).
- Trigger outbound stock retrieval based on the BOM for production jobs.
- Enforce FIFO automatically.
- Eliminate manual physical counts using live inventory tracking.
- Enable user-specific logging, performance tracking, and access permissions.
- Capture machine faults with user-level traceability.
- Verify pick/put operations via weight validation.
Lean Store/VLM Automation with Biometric Login & BOM-Based Outbound
Key Features
Biometric Machine Access
- Operators log in to the Lean Store/VLM system using fingerprint authentication.
- Each login is tagged to all subsequent actions (inbound, outbound, alerts).
- Only authorized users can access the system — ensuring accountability and preventing misuse.
- Supervisors and admins have elevated access to override or audit.
BOM-Driven Outbound Workflow
- Outbound material picks are automatically initiated based on active BOMs.
- The system receives job requirements and retrieves materials based on part code and quantity.
- FIFO logic ensures oldest stock is picked that satisfies BOM demand.
- The process is automatic and reduces manual intervention or picking errors.
Automated Storage with FIFO
- Each item is scanned during inbound and assigned a tray based on its entry time.
- System maintains batch info, expiry, and weight for each stored unit.
- FIFO is enforced through intelligent tray selection — older stock is always retrieved first.
Weight Validation
- Trays are equipped with digital weight sensors.
- During inbound/outbound, actual weight is matched against expected values.
- Mismatches trigger real-time errors, and the transaction is paused until resolved.
User Access Management
- Access levels are role-based:
- Operator: Can only execute BOM-based jobs.
- Supervisor: Can reassign, override, or audit actions.
- Maintenance: Can view system faults.
- All activities are tagged with the biometric identity of the user.
Visual Management System
- Live dashboards and Andon boards display:
- Logged-in user identity.
- Active tray status.
- Inventory availability by part number.
- FIFO alerts and machine warnings.
Workflow Overview
Biometric Login
- Operator scans fingerprint at the terminal.
- System verifies access rights and logs in.
- All actions are tracked under the operator’s ID.
Inbound Storage
- New material is scanned and assigned to a tray based on FIFO slot availability.
- Tray opens automatically; operator places material.
- Weight sensor confirms expected weight.
- System logs transaction and updates inventory.
Outbound via BOM
- Production job sends a BOM request.
- System parses required materials and quantities.
- Lean Store/VLM retrieves trays with oldest stock matching BOM.
- Operator picks; weight is validated automatically.
- Inventory is updated in real-time; transaction logged under operator ID.
Benefits
- Highly Secure Access: Biometric login prevents unauthorized access.
- Automated BOM Fulfillment: No manual part picking, reducing production delays.
- Complete FIFO Compliance: Eliminates expired or skipped stock.
- Smart Validation: Prevents errors using weight-based verification.
- Real-Time Audit Trails: Tracks who did what, when, and why.
- Space and Labor Optimization: Reduced costs, improved speed, and space.
- Fault Traceability: Machine errors linked to specific users — faster resolution.
Lessons Learned
- Ensure BOM data is clean and synchronized for automated picking.
- Train operators on biometric use and error alert responses.
- Weight tolerances should be defined based on part types for optimal validation.
- Analyze machine logs regularly to preempt performance dips.