WESTPORT FUEL SYSTEMS - Electronic Division

From Material Management to the Smart Factory

A partnership built since 2005

Westport Fuel Systems – Electronic Division is an Electronics Manufacturing Services (EMS) provider with more than 25 years of experience in high-mix electronic manufacturing. Serving industries including automotive, marine, IoT and off-highway applications, the company manages hundreds of production orders and thousands of electronic components every day across advanced SMT, THT and end-of-line assembly operations.
As production volumes increased and the business expanded into OEM manufacturing, material management became a critical success factor. Supporting a growing number of products required faster material availability, greater inventory accuracy and seamless integration between warehouse operations and production.
To support this transformation, Westport partnered with ESSEGI Automation in 2005. What started as a warehouse automation project has evolved into a fully integrated material management ecosystem comprising 15 ESSEGI AUTOMATION systems, connecting warehouse operations, ERP and SMT production into a single digital workflow.

BENEFIT: SCALABILITY
Company: EMS
Area: Cherasco, Italy (Europe)
SMT Lines number: 3 linee SMT Pick&Place
Products: ACS 1500, Ultraflex Series ISM 3600, Ultraflex Series ISM 3900, Incoming Material Station, ACS 400, ISM 500, ISM Software

We thank the company for their time and cooperation.

Automating material management has not only improved our processes: it has given us the tools to support the company’s growth and seize new business opportunities.

The starting point in Westport Fuel Systems

As production volumes increased, Westport had to manage a growing number of electronic components, making it necessary to rethink its internal material flow.

Managing higher volumes of reels required greater speed, accuracy and full traceability, while manual operations were increasingly limiting efficiency and making material handling more complex.

The goal was to streamline material management by eliminating repetitive tasks, reducing the risk of errors and creating a fully integrated flow connecting the warehouse, ERP and production lines.

The solution

Westport chose ESSEGI AUTOMATION as its technology partner to develop an automation project designed to evolve alongside the company’s needs.

The journey began with the first automated warehouses installed directly in the production area and gradually expanded over time. Today, the solution includes 15 ESSEGI systems, combining ISM Ultraflex automated warehouses, Pick-to-Light systems, Incoming Material Station and ISM Software.

Full software integration now enables an automated and connected material flow, simplifying daily operations, reducing manual tasks and ensuring reliable, shared data throughout the entire production process.

The transition was implemented gradually, without disrupting production continuity, supported at every stage by the ESSEGI Automation team.

Products featured in the Case History

ISM 3600

Incoming Material Station

ISM 500

ACS 400

ACS 1500

Software ISM

ISM 3900

WESTPORT Project: achieved goals and benefits

The implementation of ESSEGI AUTOMATION solutions has transformed material management into a digital, integrated and highly efficient process. But the most significant impact goes beyond operational optimization: it has provided Westport with a solid and scalable platform to support business growth, strengthen competitiveness and pursue new business opportunities.

Operational efficiency: Automating material storage, picking and handling has streamlined daily operations, reducing manual tasks and accelerating production order preparation. Operators can focus on higher-value activities, while materials move to production faster and through a more continuous and reliable flow
Process integration and digitalization: The integration of automated warehouses, ERP, management software and SMT lines has eliminated information fragmentation, creating a single, connected digital flow. Real-time access to up-to-date data improves coordination across departments and enables more effective production planning.
Full material traceability and control: Every component is tracked throughout the entire production process, providing greater operational control and reducing the risk of errors in component management.
Business growth and new opportunities: Digitalizing material management has strengthened Westport’s ability to respond quickly to market demands, while improving service quality and overall competitiveness. More efficient, integrated and reliable processes provide the foundation to pursue new business opportunities with greater confidence and support Westport’s evolution towards an increasingly connected, innovation-driven Smart Factory.