Mastering Parts Sequencing: Your Guide to Best Practices

Insequence pioneered parts sequencing technology and has spent nearly 30 years helping automotive suppliers establish and optimize their sequencing operations. With over 400 successful implementations across three continents and thousands of other projects, we’ve gained unmatched expertise. We have even developed software packages that enable suppliers to deliver parts to over 20 different automotive OEMs.

Simply put—we know sequencing.

Many of our customers begin their sequencing journey with little to no prior experience, but we’re there to guide them every step of the way. To share our knowledge, we’ve compiled these best practices guide, drawing on insights from across our company to help suppliers confidently navigate the complexities of sequencing.

What is parts sequencing?

Parts sequencing or sequencing is a process where a supplier delivers parts to an OEM assembly plant in an exact order as required by the OEM. It is a strategy used for lean manufacturing to reduce the need for standing inventory. This process can also be referred to as just-in-sequence (JIS), in line vehicle sequencing (ILVS), and sequential parts delivery (SPD).

11 Key objectives for effective parts sequencing

We have identified 11 critical areas that suppliers must master to ensure seamless sequencing. While this may seem extensive, sequencing is a highly interconnected process where every detail plays a vital role.

1. Seamless communication with OEMs
2. Robust parts sequencing technology
3. Efficient inventory management
4. Flexibility in production
5. Comprehensive support and maintenance
6. Collaborative operational framework
7. Quality assurance
8. Streamlined logistics
9. Proactive risk management
10. Continuous improvement and employee training
11. Regulatory compliance and security

1. Seamless Communication with OEMs

Effective parts sequencing starts with seamless communication between suppliers and OEMs. Since each OEM has its own method of conveying demand, integrating the right technology is essential.

• EDI Integration: Process Electronic Data Interchange (EDI) to receive demand changes, such as DELJIT, DELJIT SYNCHRO, and production schedules in real-time.
  
  
• Real-Time Data Exchange: Maintain constant visibility into OEM sequencing requirements, including Just-in-Time (JIT) and Just-in-Sequence (JIS) demands.
  
  
• Standardized Communication Protocols: Establish interfaces with OEM Broadcast systems to ensure efficient and accurate data exchanges.

2. Robust Parts Sequencing Technology

Investing in the right technology and structured processes is key to achieving a seamless and reliable sequencing operation. A robust parts sequencing system lays the foundation for an efficient, error-free production process, helping manufacturers enhance accuracy, minimize downtime, and improve workflow efficiency.

• Advanced Sequencing Software: Implement tools like Insequence Software Suite for Sequential Parts Delivery to automate sequencing and minimize human error.
  
  
• Error Prevention Mechanisms: Use built-in error checking to detect and prevent mistakes such as incorrect scans or rack placements.
  
  
• Test Environments: Ensure all new applications and process changes are tested in a dedicated test environment prior to implementation in production. Up-To-Date hardware and software are necessary for these environments to maintain production stability.
  
  
• Well-Defined Processes: A well-structured sequencing process is essential, requiring both precise software logic and clear operational procedures. While the software ensures parts are sequenced accurately, teams must follow defined processes to maintain system performance and respond quickly to any errors. Together, they keep production running efficiently and without disruption.

3. Efficient Inventory Management

Effective inventory management keeps production running smoothly by preventing shortages and excess stock. Leveraging the right systems and practices ensures accurate tracking, optimized stock levels, and up-to-date data for seamless operations.

• Inventory Tracking: Leverage an Inventory Management System (IMS) to maintain accurate stock levels, minimizing disruptions to production.
  
  
• Part Data Maintenance: Maintain part master data, Bills of Materials (BOM), and new part numbers. Keeping data current is essential for smooth operations.

4. Flexibility in Production

Flexibility in production is essential for adapting to changing demands and manufacturing conditions. By integrating adaptable sequencing software, dynamic scheduling tools, and seamless MES integration, manufacturers can maintain efficiency while ensuring accuracy and traceability.

• Handling Variability: Account for BOM (Bill of Materials) changes and adapt sequencing software for non-sequenced production when necessary.
  
  
• Manufacturing: If the sequenced part is also manufactured on site, using a table-driven MES system provides flexibility on the production line by easily adapting to changes and variations. Seamless integration between MES and sequencing helps reduce errors and creates a unified database, which improves traceability throughout the manufacturing process.
  
  
• Dynamic Scheduling: In the case of non-sequenced production, use tools like the Production Scheduler to handle varying demand from multiple OEMs, file formats, and shipping locations.
  
  
• Process Changes: Document, communicate, and test any process or production environment changes before implementing them to prevent disruptions.

5. Comprehensive Support and Maintenance

Comprehensive support and maintenance are crucial for ensuring a reliable and efficient sequencing system. From IT oversight and server upkeep to database management and data redundancy, proactive maintenance minimizes downtime and keeps operations running smoothly.

• Dedicated IT Resource: The Sequencer should have a dedicated, well-trained IT resource responsible for overseeing and maintaining the sequencing system, troubleshooting issues, and ensuring seamless system functionality.
  
  
• Server Maintenance: Perform regular server upkeep, including installing Windows updates, antivirus management, and hardware maintenance such as replacing hard drives and RAM.
  
  
• Database Maintenance: Conduct database maintenance regularly (at least weekly for large volumes) to optimize database performance and ensure sufficient disc space by offloading backups older than two weeks.
  
  
• Site Infrastructure: Properly upkeep and maintain networking, PLCs, torque controllers, testers, welders, and any hardware tied to the production line.
  
  
• Data Redundancy: Ensure backing up of data is being completed whether doing this through SQL Mirroring or VM snapshots, etc.
  
  
• Off-Network DB Backups: Ensure regular DB backups are being maintained outside the network in the case of cyber-attacks or DB corruption.

6. Collaborative Operational Framework

By incorporating dedicated IT resources and fostering collaboration between engineering, IT, and Operations Teams automotive sequencing suppliers can establish a robust and cohesive operational framework. This collaborative approach ensures:

• Seamless Technology Integration: Engineering and IT work together to align systems, processes, and technology for efficient operations.
  
  
• Enhanced Manufacturing Performance: Cross-functional teamwork resolves issues quickly and optimizes production workflows.
  
  
• Continuous Innovation: Collaboration helps teams create innovative solutions to meet evolving OEM requirements and adapt to industry changes.
  
  
• Continued Efficiency: By operations communicating issues and inefficiencies in process with IT and engineering future critical issues can be mitigated.

7. Quality Assurance

Quality assurance is essential for maintaining accuracy and meeting OEM standards in parts sequencing. Implementing standardized quality checks, thorough software testing, and strong application security helps ensure a reliable and error-free production process.

• Standardized Quality Checks: Establish quality control measures (such as using Insequence Host Module) to ensure parts are sequenced accurately and meet OEM standards.
  
  
• Software Testing: Actively test customizations or requested changes on a dedicated test server to ensure smooth transitions to production.
  
  
• Application Security: Maintain application security by managing user permissions, securing admin passwords, and updating access levels as needed.

8. Streamlined Logistics

Streamlined logistics ensure that parts are delivered accurately and on time to OEMs. By optimizing rack loading and tracking shipments, suppliers can maintain smooth and reliable operations.

• Precise Rack Loading: Streamline rack loading processes to ensure parts are delivered to OEMs in the correct sequence.
  
  
• Shipment Tracking: Use ASNs and shipment tracking to provide OEMs with visibility into delivery schedules.
  
  

9. Proactive Risk Management

Proactive risk management helps prevent disruptions and optimize performance in sequencing operations. By implementing contingency plans, carefully managing production changes, and conducting regular risk assessments, manufacturers can ensure system stability and reliability.

• Contingency Planning: Prepare for potential disruptions (e.g., hardware failures or supply chain issues) with redundant systems and regular testing.
  
  
• Changes to Production Environment: Allow adequate time for implementing and testing changes to avoid disruptions to live production.
  
  
• Risk Assessment: Proactive risk assessment helps reduce operational risks and can often help optimize performance. This is recommended to be performed every 1 to 2 years depending on volume of the system and process change frequency.
  
  Insequence offers a proactive Risk Assessment and Optimization service tailored to the Insequence system. What this service looks for ranges from finding errors that run the chance of shutting down an OEM to making sure the site is within accepted standards.

10. Continuous Improvement and Employee Training

Continuous improvement and employee training are key to maintaining an efficient sequencing operation. Ongoing training, operational reviews to eliminate inefficiencies, and close collaboration with OEMs help enhance productivity and adapt to evolving demands.

• Regular Training: Ensure all personnel working with the sequencing software are adequately trained. Training for supervisors and admins should include configuration management, adding parts, creating BOMs, and performing minor process changes.
  
  
• Eliminate Waste: Continuously review operations to remove inefficiencies and improve productivity.
  
  
• Customer Collaboration: Work closely with OEMs and suppliers to refine processes and address challenges proactively.

11. Regulatory Compliance and Security

Regulatory compliance and security are essential for maintaining quality, safety, and data integrity. Adhering to industry standards and implementing strong security measures ensures reliable operations and protects sensitive information.

• Adherence to Standards: Comply with all OEM required standards, and other relevant quality and safety requirements.
  
  
• Data Security: Maintain secure storage and transmission of data. Customers are responsible for maintaining all application-level security protocols after initial setup.

About Insequence

Insequence is a global leader in automotive manufacturing software and services. Nearly three decades ago we created parts sequencing technology that to this day stands as a paradigm shift in industry line operations.  Today, Insequence provides an integrated suite of manufacturing and logistics technology solutions to companies that supply parts to the world’s automotive original equipment manufacturers (OEMs).

Insequence serves hundreds of customers across North America, South America, and Europe, offering dozens of standard automotive OEM interfaces and 24/7/365 customer support. As a leading provider of supply chain software solutions, Insequence continues to work with its very first customer from 1996.

About the Authors

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Jason Wynne
Vice President of Technology and Project Management

Tina Rion
Director of Client Success

Rachel Apsey
Marketing Manager

Karl Randolph
Accounts Manager, North America