case study

Labels, non-conformities, hidden costs: how to secure traceability in Body in White?

An underestimated total cost of marking and labeling on BIW lines

Beyond operational challenges, the labeling solution had a high total cost of ownership.

Implementing the system required an initial investment of approximately €80,000, including:

• An industrial printer
• An automatic label application system (often complex)
• Connections to the line PLC
• Verification/reading equipment
• The time and resources required for process setup and optimization

On top of this, there were significant recurring costs:

• Consumables (labels, ink)
• Supply, storage, and handling operations
• Regular maintenance of the solution, both during operation and restart phases
• Management of non-conformities related to identification loss

These recurring indirect costs, combined with limited reliability, impacted the overall line performance and were estimated at €20k per year.

Industrial objectives for marking and traceability of cross members in Body in White

This OEM had two main objectives:

1. Reliability and traceability: ensure permanent marking directly on
   steel cross members coated with cataphoresis, while meeting corrosion resistance requirements and eliminating the risk of critical data loss.
2. Cost reduction and ROI: eliminate consumables and maintenance associated with printers

Technical constraints and challenges of laser marking on steel cross members

The project involved several major technical and industrial constraints:

• Ensuring laser safety without adding a dedicated enclosure
• Preserving the KTL coating without functional degradation
• Ensuring long-term traceability reliability directly on the part
• Meeting the production rate of 6 parts per minute
• Operating reliably in a constrained BIW environment exposed to dust, oil, and vibrations
• Integrating into the existing production line without requiring changes to the process, line organization, or communication protocols

Initial label / Final laser marking

SIC MARKING solution: FIT laser marking integrated into the Body in White line

To meet these requirements, SIC Marking proposed its FIT laser marking solution, directly integrated into the Body in White production line.

The marking is performed directly on the steel cross member in the form of a permanent barcode that is readable and durable.

Key advantages of the FIT solution for traceability and industrial reliability:

• Direct and permanent marking, with no risk of peeling
• No consumables required, meaning no recurring identification costs
• Preservation of the KTL / cataphoresis coating
• Integrated safety, with no need for a dedicated enclosure
• No contact or complex mechanisms, resulting in minimal maintenance
• Line stop and restart without maintenance of traceability equipment
• Compatibility with high production rates of 6 parts per minute

Thus, the laser solution completely replaces the printer and labeling system, while simplifying integration and maintenance.

Implementation of laser marking on the Body in White line: integration and safety for cross members

The project was deployed in several stages to ensure secure industrial integration:

1. Preliminary testing on steel cross members to adjust laser parameters and ensure the readability of the barcode
2. Marking validation ensuring barcode compliance, as well as preservation of the protective e-coat without functional degradation
3. Installation and integration of the FIT solution directly on the line, ensuring operator safety

Example of a 500-hour salt spray test result

Results achieved: permanent traceability and cost reduction with laser marking

• Reliable and permanent traceability across all cross members
• Marking validated on cataphoresis / KTL coating, without degradation
• Complete elimination of consumables (labels and ink), generating direct savings of €20k per year
• Significant reduction in maintenance
• Salt spray test report validated, ensuring marking resistance to industrial and corrosion conditions
• Significant reduction in non-conformities related to label peeling
• Maintained production rate of 6 parts per minute without slowing production
• Estimated return on investment of approximately 1.5 years

Conclusion

By replacing labeling with permanent laser marking, this manufacturer has sustainably secured the traceability of its cross members in a Body in White environment, while reducing overall costs and preserving its existing production process.

SIC Marking’s FIT solution demonstrates that it is possible to eliminate labels without impacting the production line, while improving reliability, industrial performance, and compliance, with an ROI of around one year.