Insequence MES solution enhances NYX’s efficiency and quality

This study is based on a discussion with a Scott Kilby, Sequencing Manager for NYX, as part of an ongoing case study.

Case Study Overview

NYX has been using Insequence since 2003, starting with a single Manufacturing Execution System (MES) line manufacturing parts for Ford. Over the past decade, they have expanded significantly, with every stage of growth supported by Insequence software solutions.

After successfully implementing their Ford program, NYX secured the next platform of that program and more. As operations grew, NYX opened new facilities in the U.S. and Mexico, all utilizing Insequence solutions. They also partnered with another company to support its parts sequencing operations that would also use Insequence solutions. Additionally, NYX is replacing an existing system with Insequence at yet another one of their facilities.

This long-standing partnership continues to drive efficiency, scalability, and innovation across the company’s operations. NYX has never encountered a situation where the answer was “no” when working with a customer (OEM). They’ve been able to use Insequence software to accomplish virtually any task the plant or customer presents, ensuring that parts are produced to specific quality standards and can be reworked as needed.

About Insequence

Insequence is a leading provider of automotive manufacturing and logistics software, supporting many of the world’s largest automotive suppliers for more than 20 different automotive OEMs. 

• Software Solutions Provider for automotive suppliers
• Solutions include Manufacturing/MES, Parts Sequencing, SCADA, Inventory, Data Warehousing, and Batch Production
• First software implementation in 1996
• Supports customers in North America, South America, and Europe
• Software solutions empowering automotive suppliers to deliver parts to over 20 different OEMs
• Offers 24x7x365 support via phone, online chat, and email

About NYX

NYX, based in Livonia, Michigan, is a full-service automotive supplier specializing in plastics processing, assembly, and interior craftsmanship, delivering complete manufacturing solutions from concept to production.

• Tier One automotive supplier
• Company’s OEM Experience includes Ford, GM, Honda, Tesla, and more.
• Insequence customer since 2003
• NYX utilizes Insequence MES and Parts Sequencing solutions
• Operates facilities that utilize Insequence in the USA and Mexico
• Scott Kilby, Sequencing Manager for NYX, has over 12 years of experience with Insequence solutions

What does NYX use Insequence for?

NYX uses Insequence’s Manufacturing Execution MES to support their advanced manufacturing processes, while utilizing Insequence Sequencing for rack loading and pick-and-pack.

Their primary customers are Ford and GM, with additional experience supporting Honda and Tesla amongst others.

Insequence software has been configured to enable automotive suppliers to optimally serve over 20 automotive OEMs, including Ford, GM, Honda, and Tesla.

Ensuring Quality Through Granular Traceability

Insequence MES provides granular traceability, with the Birth History Report (see example below) being one of NYX’s most utilized features. This built-in report is deployed across all sites, ensuring complete visibility into every part produced.

For each part, NYX can track detailed production data, including torque results, continuity results, scan data, and more.
If an issue arises, NYX customers can provide any label on the part, allowing them to quickly retrieve its production history. This enables fast and precise root cause analysis—whether the issue stems from a supplier mismatch or an internal change—helping to resolve problems efficiently and maintain high-quality standards.

Below is an example of the NYX Birth History Report.

Empowering Complex Manufacturing with Flexibility

When discussing Insequence’s flexibility, Scott Kilby shared “With our customers [OEMs], adaptability is the name of the game. They constantly ask us, ‘Can we do this?’ And the answer invariably has been yes.” Insequence provides the adaptability and capability suppliers need to build robust and complex production lines, ensuring they can meet ever-changing OEM demands with confidence.

For example, one GM program NYX has supported for approximately eight years involved manufacturing center consoles. Recently, they were awarded the next phase of this program, securing a second platform. When redesigning the production line, NYX continued using Insequence solutions, ensuring a seamless transition with no issues from the old line to the new.

By providing the right tools, Insequence has enabled NYX to design and operate highly sophisticated production lines, allowing them to take on even the most complex manufacturing challenges.

Award-Winning Quality with Insequence

On every production line running Insequence, NYX has achieved the highest quality awards. They have consistently been recognized as Supplier of the Year by both Ford and GM, year after year.

“Any line that we use Insequence products on,
we have not missed a beat.”

Scott Kilby, NYX Sequencing Manager

Streamlining Training and Workforce Efficiency

A key benefit NYX enjoys with Insequence is the ability to integrate work instructions directly onto the operator screen for every step of the production process. This has significantly improved training, especially at sites with high turnover or those adding second and third shifts to meet production demands.

The ability to quickly and seamlessly train new operators without requiring them to start on the first shift and gradually transition to another has been a major advantage, ensuring efficiency and consistency.

Custom Solution to Streamline New Install

One of the NYX sites is replacing an existing system with Insequence software. Since personnel were already trained on an existing process, the company requested unique software enhancements to retain this workflow and minimize growing pains. Specifically, they needed the ability to skip a part, move it to a separate queue, and return to it later to complete and fill the racks.

This enhancement allowed the plant to maintain their existing process while successfully implementing Insequence software. Not only did this preserve the workflow, but the enhancement goes a step further, ensuring that nothing is missing or mis-sequenced when the racks are shipped, guaranteeing complete accuracy and quality control.

Over the years, the Insequence development team has been incredibly receptive, addressing requests for features that the software may not yet offer or when NYX requires unique or out-of-the-box solutions. They have great confidence in Insequence, knowing that if they ever encounter an unfamiliar task, they can rely on the support staff to provide quick and effective solutions.