In discrete assembly the thing you manage is not a batch, it is an individual unit. Vegam gives each serial its own manufacturing history: the parts that went in, the stations it passed, the values it was tested at, and every time it went round again.
Every unit traced. Every test bound to its serial. Every rework loop counted.
Genealogy breaks between stations and between suppliers, so a field failure cannot be resolved to specific units.
Rework loops consume capacity that nobody measures, so the cost of poor quality is absorbed rather than attacked.
In-process quality lives on paper, separate from the build record it belongs to.
Stations work from printed instructions that are hard to keep current, so units get built to a drawing that has moved on.
One serial, its whole manufacturing history: the lots that went into it, the stations it passed, the operator on shift, the values it was measured at, and what happened when it failed.
Illustrative unit history. Serial, lot and work-order identifiers are examples.
Nine stages from the work order to the shipment. Click a stage to see the operational reality, and what changes when the serial carries its own record.
CONCURRENT · Rework is a feedback branch off in-process inspection (IATF 16949 §8.7), not a linear step. Reworked units carry updated genealogy back into the flow.
The chain below is per serial, not per batch. That is the difference between knowing a lot was affected and knowing which units were.
Released against the current revision and live capacity.
Lots picked, staged and consumed against this specific unit.
Routing enforced, so stations cannot be skipped or taken out of order.
Certification checked at the station before work is accepted.
Torque, dimension and process values captured as the build happens.
Results bound to the serial, with the parameters it was tested at.
A counted branch with its own cause, not a silent second pass.
Genealogy sealed per unit, so a field failure resolves to specific serials.
Every unit traced through every station, forward and backward.
The rework branch measured by cause, station and cost rather than absorbed.
Checks enforced in the routing, so a unit cannot pass a station incomplete.
Test data bound to the serial, with the parameters that unit was tested at.
Bring one assembly line and its rework loop. We’ll map where the genealogy breaks and show what changes when every serial carries its own record.