Sungwon PF,
together with Innobase, implemented real-time production and process management to realize a "visual digital shop-floor management" system accessible from anywhere — building a fast and consistent manufacturing environment.
Founded in 1979, Sungwon PF is a global automotive parts manufacturer producing everything from small components such as clips, bushes, and brackets to functional and exterior parts such as sunroofs. Backed by more than 45 years of proprietary technology, the company holds ISO 16949 certification as well as Hyundai and Kia SQ (Supplier Quality) certification.
As a company leading the way in advanced automotive culture today, Sungwon PF puts customer satisfaction first across development, quality, and service, striving to anticipate customer needs and offer solutions before being asked. Recognizing that maintaining globally competitive technology is fundamental to delivering that satisfaction, the company invests generously across all areas, including R&D and system development.
Since its founding in 1979, Sungwon PF has continually pursued the pinnacle of technology and quality, leading the way in advanced automotive culture. As a long-established company with expertise in mold design, multi-forming, and press processing, it holds the delivery of defect-free products that customers can trust as its top priority. Striving to make every process from production to shipment more complete than before, the company recognized the need for a better system and set out to build a "visual digital shop-floor management" system.
Previously, production performance and status, along with product location and shipment, were all tallied and managed manually — making it difficult to track real-time production information, product location, inventory levels, and available warehouse space. In addition, because product locations were manually recorded on shipping instructions to verify location and product, there was a risk of shipping errors, and the same risk of manual-entry mistakes persisted throughout the process, leading to inefficiencies such as wasted time and labor.
Sungwon PF's goals were to lay the foundation for a sustainable operating system through an intelligent information system; to maximize management capability and achieve quality management by quickly establishing a standardized management framework — thereby enhancing its corporate image and improving customer satisfaction; and to build a foundation for growth on that basis.
Before building the system to achieve these goals, one thing had to be addressed first: establishing a barcode system and its supporting information infrastructure. To do this, Innobase applied barcodes (for both receiving and shipping) built on a consistent rule set assigned to products and parts — for example, Customer + Lot No. + Part No. + Type_Weight + Ser No. — and built the barcode information infrastructure needed to minimize human error such as shipping and delivery mistakes, while enabling a real-time information environment through mobile devices.
To address the inability to track real-time production information — since both production performance and status had been managed and tallied manually — Innobase built a production monitoring system using shop-floor touch PCs and tablets that process performance data in real time and automatically manage results. This made real-time performance monitoring possible, simplifying on-site management and enabling a quick response to issues that arise during the process.
Product and material management, and the shipping management built on top of them, were also improved. Location barcodes (metal tags) were attached by warehouse and location to provide real-time product location information, making it easy to locate products during transfer and shortening picking time. This carried through to shipping as well: checking shipping instructions via tablet improved both accuracy and speed while eliminating the risk of shipping errors. In addition, managing location barcodes (location tags) within the warehouse made it possible to quickly identify long-term inventory and available space, enabling better management of aging or obsolete stock — which in turn reduced inventory costs.
Sungwon PF is a company wholeheartedly committed to leading advanced automotive culture and supplying defect-free products that customers can trust. This meant the company needed to manage its production processes even more thoroughly, and to tighten control over every step from manufacturing through to trouble-free shipment.
Based on Sungwon PF's goals, Innobase defined the required improvements and designed an architecture tailored to the company's existing equipment. Through an intelligent information system built on real-time data collection, aggregation, and analysis — covering real-time production monitoring, material location management, plan-versus-actual performance tracking, and product loading and shipping management — Innobase helped realize the "visual digital shop-floor management" system and lay the foundation for a sustainable operating structure. Fast, consistent sharing and awareness of shop-floor data efficiently supported collaboration between related departments and accelerated decision-making. It also secured quality reliability across manufacturing activities and finished products, enhancing the company's image and playing a major role in achieving Sungwon PF's ultimate goal: earning customer trust.
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