Automotive MES Platform for Production Excellence and Optimization

The main focus was to introduce a custom Manufacturing Execution System (MES) with integrated CRM functionality across many manufacturing locations. The platform has ensured full production visibility, process traceability, and workflow automation across multiple manufacturing lines, contractors, and brands.

Referred to us by a mutual contact, the client required a scalable solution to unify production monitoring, streamline communication across time zones, and integrate seamlessly with Siemens sensors on site. The goal was to reduce defects, enhance operator efficiency, and centralize overall decision-making, improving business performance at large.

12 experts allocated (3 per brand), ensuring personalized attention to each production line while maintaining a cohesive product vision. Each group included a full-stack developer, a UX/UI designer, and a QA specialist.

The unique set of challenges stemmed from the need to align multi-brand operations across different time zones, integrate legacy systems with modern IoT devices like Siemens sensors, and ensure seamless scalability without disrupting existing workflows. The major difficulties included:

• Synchronizing teams across different time zones,
• Integrating legacy systems and Siemens hardware,
• Maintaining brand-specific workflows without duplicating codebases,
• Automotive manufacturing demands strict compliance with industry standards and traceability at every stage: parts, people, and processes,
• The client needed deeper insights into the causes of downtime and quality issues to reduce waste and improve performance metrics like OEE.

Backend: .NET, MS SQL

Frontend: MVC, JQuery

Hardware Integration: Siemens sensors across all facility nodes

To address the industry-specific challenges, we’ve delivered a comprehensive solution. A robust Enterprise Manufacturing System has been designed to unify operations, enhance process visibility and control, and optimize every stage of the production cycle:

• Real-time Production KPIs: Live dashboards display metrics like part counts, station uptime, and operator performance. Supervisors get instant visibility into how each workstation is performing, with color-coded alerts for delays or quality drops.
• Cloud Infrastructure for Scalability: The system is deployed in the cloud to ensure high availability, seamless updates, and easy scaling across multiple brands or manufacturing sites, while reducing infrastructure maintenance efforts.
• Production Reporting and Statistical Process Control (SPC): Automated reports track trends and anomalies across production shifts. SPC tools help detect variations early, enabling proactive adjustments and maintaining high-quality standards.
• Full Compliance with Automotive Manufacturing Standards: Built-in compliance tracking ensures all workflows meet industry norms. In particular, every component and process is logged and auditable, simplifying inspections and certification renewal processes.
• Smart Production Scheduling: The platform auto-generates production schedules based on real-time capacity, order priority, and resource availability, while managers can manually override or approve optimized plans easily.
• Track & Trace System: The system logs each spare part’s journey through the plant. This ensures end-to-end traceability, simplifying recalls, warranty tracking, and compliance audits.
• Staff and Shift Management: Supervisors assign roles, manage shifts, and monitor operator performance through a central console. Built-in logic prevents overbooking and supports compliance with labor regulations.
• Warehouse and Inventory Control: Inventory levels are synced with production in real-time. The system tracks incoming parts, consumption rates, and alerts for restocking or anomalies in supply chain flow.
• Quality Control and Issue Tracking: QC checks are firmly embedded in the workflow. Defects are logged with photos, root causes, and resolutions. The issue tracker supports tagging, assigning, and escalation to managers or engineers.
• Component Sequencing: For assembly lines requiring specific build sequences, the system ensures parts arrive just-in-time and in the right order, reducing storage needs and minimizing errors.
• Interactive Work Instructions: Digital instructions replace paper manuals. Operators view step-by-step guides, checklists, and 3D visuals, improving accuracy, training efficiency, and preventing human errors.
• Predictive Maintenance Assistant: Sensor data signals about equipment wear and schedules service before breakdowns occur. As a result, they prevent business interruption in most cases.
• Vendor Rating and Supply Evaluation: The system evaluates suppliers based on delivery timeliness, part quality, and defect rates. Such reports support better purchasing decisions and future negotiations.
• Managerial Reporting: The platform generates daily, weekly, and custom reports with key production metrics, quality trends, and downtime causes, giving leadership the data to make strategic decisions.

The implementation has led to improved operational efficiency, quality control, and decision-making across the production floor.

• 70% Achieved OEE: Overall Equipment Effectiveness (OEE) is a global benchmark metric combining Availability, Performance, and Quality. It confirms that the plant is producing at 70% of its full potential, above average for complex multi-brand automotive production.
• 25% Less Disruption of Supply Chains: Every production stop is recorded with cause, duration, and affected station. This helps identify recurring issues (e.g., machine faults, material shortages) and prioritize fixes to minimize future downtime.
• Zero-Defect Production Monitoring: The system continuously tracks product quality during manufacturing, flagging any deviation from set standards immediately. This allows operators to correct issues in real time, preventing defective parts from moving downstream.
• 15% Less Cost Losses Resulted from Scrap and Low Quality: Incoming parts are evaluated based on defect rates, delivery reliability, and usage outcomes. Vendors receive performance scores, which help in selecting or replacing suppliers.
• No Shortage or Surplus of Spare Parts: Every workstation is monitored in real time, with dashboards showing stock, cycle time, and productivity. Supervisors can spot inefficiencies instantly and rebalance workloads as needed.
• Better Operator Performance: Since each operator’s productivity and accuracy are evaluated based on real-time metrics such as throughput, error rates, and time on task, this fosters accountability and helps identify training needs.