IntelliWORKS Replaces Legacy MES Improving Sequencing and Traceability for Automotive Interior Manufacturer

A leading North American manufacturer of interior automotive components offers a range of services including material compounding, injection molding, sequencing, assembly, cast skin and foam, and automotive interior design.

Challenge: Disparate MESʼ

The automotive interior manufacturer was using two different manufacturing execution systems (MES) for its instrument panel and door lines. One MES was Pyramid Solutionsʼ IntelliWORKS and the other a competitor. Disparate systems were causing two major problems:

1. It was not economically sustainable to continue 24/7 support and maintenance for two MES systems.
2. Traceability was difficult because there were gaps between OEMs and each MES.

Additionally, the other MES system was struggling to evolve with advancements in technology. For example, when the manufacturer wanted to adopt laser scoring or robots into its manufacturing lines, it was limited in how the lines communicated with each other.

The manager of information technology at the manufacturer took a deep dive researching the potential of their current MES systems and other systems on the market.

“I talked to other organizations about their MES and every single one of them shared severe limitations and frustrations,ˮ he said. “When I talked to Pyramid Solutions about potentially expanding their MES, it became clear that their capabilities far outshone what the other manufacturing execution systems were doing.ˮ

Solution: IntelliWORKS

After collaborating with Pyramid Solutions and learning about how IntelliWORKS could grow to meet the manufacturerʼs needs, the company began replacing its other MES. Today, approximately 300 stations across all facilities use IntelliWORKS with 140 more stations planned to come online in 2025.

IntelliWORKS is an integrated MES solution that offers sequencing, error-proofing, defect tracking, packout and labeling, and traceability.

For the automotive interior manufacturer, sequencing and traceability were major benefits to its operations.

“Sequencing is one of the most important IntelliWORKS features to us. It saves us time and money,ˮ the information technology (IT) manager said.

For example, if the manufacturer is producing an instrument pad and certain parts are identified as key components, and one of those key components is missing, IntelliWORKS notifies the operator immediately and prevents the instrument pad from moving forward to the next station. Prior to IntelliWORKS, the manufacturer relied on operators to see and identify issues – a fallible process. IntelliWORKS adds process integrity and prevents errors from moving down the line.

IntelliWORKSʼ flexible and user-friendly design with an easy-to-use GUI makes it an attractive solution.

Not only does IntelliWORKS exceed the automotive interior manufacturerʼs expectations, but the Pyramid Solutions team does too.

“Pyramid Solutions has a good understanding of the industry. They offer ideas and strategic thought,ˮ the IT manager commented. “They have truly been a partner who is invested in improving our processes.ˮ

Another benefit of working with Pyramid Solutions is the comprehensive support it provides.

“Iʼve been blown away at their quick responses,ˮ he said. “If I call with a problem, theyʼre on the phone immediately looking for solutions or workarounds to get us up and running while investigating a permanent solution.ˮ

This kind of support is invaluable when every second of downtime equates to lost revenue for the automotive interior manufacturer and its OEM.

“Iʼve recommended Pyramid Solutions to many people,ˮ the IT manager said with a smile. “Their support, flexibility, capabilities and understanding of manufacturing execution systems are unmatched in the industry.ˮ

Interested in learning more about how IntelliWORKS could optimize your operations? Explore our webpage or reach out to our team.