Barcode labels and handheld scanners are also an important part of every Plexus Online implementation, enabling operators and material handlers to quickly and efficiently move materials around the shop floor. In less than a year, the quality performance (as measured in parts-per-million defective) has been reduced from over a thousand in 2004 with the previous supplier, to six ppm in 2005 with ByTec. A part that was a costly struggle for another company has become profitable for ByTec. Moreover, the combined capabilities of process control and traceability have allowed ByTec not only to produce the UCB without major problems, but also to make multiple design changes that have radically improved the part's performance.
Having succeeded with the initial goal for the Visteon UCB, ByTec and Visteon are now planning the next phase of the project, which involves tying the UCB serial number to the Ford vehicle identification number (VIN). In addition, ByTec has recently re-sourced the components of the UCB, including the rubber provider, to companies that also utilize Plexus Online. This will allow the UCB components to be traced not just within ByTec and Visteon, but across the entire extended supply chain.
With the success of this first traceability project, ByTec's OEM and tier-one customers are indicating that more business will be forthcoming. Most recently, ByTec has decided to move forward with a full implementation of Plexus Online across its entire organization, so that Plexus Online handles all its manufacturing lines and manages all aspects of its business — from shop floor to top floor.