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Automotive Supplier Achieves 30% Downtime Reduction

Discover how a leading automotive parts manufacturer used Micraft MES to optimize production, reduce downtime, and improve traceability across multiple plants.

  • Client: Leading Automotive Supplier
  • Category: Manufacturing Execution System (MES)
  • Date: 24th July, 2024
  • Industry: Automotive Parts Manufacturing

Micraft MES transformed production by bringing real-time visibility and actionable insights across four manufacturing facilities.

Challenge

Frequent unplanned downtime and lack of real-time production visibility across multiple plants created operational inefficiencies, delays, and rising maintenance costs. The client needed a solution that could provide live production data, reduce downtime, and improve collaboration across facilities.

  • Machines often stopped unexpectedly without timely alerts.
  • Lack of standardized processes across 4 manufacturing sites.
  • No real-time visibility for managers, causing delayed decisions.
  • Rising scrap and rework due to missing root-cause insights.
  • Manual reporting slowed communication between operators and supervisors.
  • Overall Equipment Effectiveness (OEE) was declining each quarter.
Challenge

Solution

Micraft MES was deployed to monitor machines in real time, track downtime events, and provide operators with digital work instructions. Automated alerts ensured faster issue resolution and improved communication between production teams.

  • Real-time machine monitoring with instant dashboards.
  • Automated downtime tracking and root-cause classification.
  • Standardized workflows across all manufacturing plants.
  • Digital work instructions reduced errors and training time.
  • Mobile alerts enabled supervisors to act immediately.
  • Improved OEE visibility with detailed analytics and reports.
Solution

Implementation

The MES was seamlessly integrated with the client’s existing ERP and PLCs. Operator training was conducted in phases, and the system was rolled out across 4 facilities to ensure minimal disruption during deployment.

Real-time synchronization allowed accurate production tracking, while role-based access improved data security. Automated reports reduced manual effort and helped managers take quicker decisions. A dedicated support team ensured smooth adoption and continuous improvement throughout the rollout.

System Integration

MES integrated with ERP & PLCs for smooth data flow and centralized monitoring.

Operator Training

Step-by-step training sessions reduced learning curve and improved adoption.

Phased Rollout

Deployed across 4 facilities in phases, ensuring minimal disruption to operations.

Performance Monitoring

Live dashboards tracked rollout performance and provided quick feedback loops.

Key Features

Key Features Used

  • ✔ Real-time dashboards for production visibility
  • ✔ Automated alerts for faster response to issues
  • ✔ Electronic work orders and step-by-step instructions
  • ✔ Root cause analysis tools for quick problem-solving
  • ✔ Predictive maintenance scheduling to reduce downtime
  • ✔ Centralized data management ensuring single source of truth
  • ✔ Mobile/tablet access for operators on the shop floor
  • ✔ Role-based access control to enhance security
  • ✔ Integration with ERP & PLCs for smooth data flow
  • ✔ Automated compliance & audit reports generation

Results

The client achieved a 30% reduction in downtime, improved traceability, and actionable analytics that enabled continuous improvement. The system also ensured faster responses to production issues, reducing delays and scrap rates.

  • 15% increase in overall equipment effectiveness (OEE)
  • 20% faster issue resolution time
  • Improved first-pass yield and product quality
  • Enhanced employee productivity with digital instructions
  • Better compliance with industry standards & audits

ROI

Micraft MES delivered payback within 9 months through reduced scrap, higher throughput, and lower maintenance costs. The client experienced tangible financial benefits with improved operational excellence.

  • 25% cost savings on raw material wastage
  • 15% reduction in unplanned maintenance costs
  • 10% increase in production capacity utilization
  • Rapid ROI with long-term sustainability & scalability
  • Strong competitive edge with data-driven decision making

Testimonial: “Micraft MES gave us the visibility and control we needed to drive operational excellence across our plants.”