Leveraging MES Integration for Operational Excellence in A Green Field Automotive Stamping Plant: A Digital Transformation Case Study
Year: 2025
Type: article
Abstract: This study investigates the implementation of a Manufacturing Execution System (MES) in a newly established automotive stamping facility featuring a tandem press line. Unlike retrofit scenarios, the MES was integrated during the plant design stage, enabling deep alignment be-tween digital systems and shop floor operations. The research evaluates MES performance across seven months, focusing on changeover optimization, quality control, traceability, and Overall Equipment Effectiveness (OEE) enhancement. Real-time data collection, standardized workflows, and user adaptation contributed to early process stabilization and efficiency gains. The introduction of the MES played a pivotal role in achieving early control and standardization of key production indicators. OEE increased steadily - from 47.17% in the first month of operations (September 2024) to 72.36% by the seventh month (March 2025). The availability of real-time production data contributed to a 37.5% decline in changeover durations, while the defect rate dropped significantly - from 8.22% to just 1.93%. From the very first production cycle, the system ensured comprehensive digital traceability, covering raw materials, equipment performance, and operator activity. These outcomes serve as a reference framework for implementing MES solutions in green field environments - particularly in high-throughput sectors such as automotive stamping. By embedding MES at the foundational stage, plant commissioning transitions from a linear setup process to a feedback-driven optimization cycle. This approach accelerates efficiency gains, enforces operational consistency, and expedites digital maturity from the outset. The case demonstrates how MES, when deployed from inception, can accelerate digital maturity, ensure compliance, and support long-term operational scalability.
DOI: 10.14419/033gde10
Authors: Piyush Dipak Bachhav, Sudhir Madhav Patil, Mitesh Shashikant Jadhav, Harsh Dilip Kene
Institutions: COEP Technological University, Mahindra Group (India)
Language: English
Subfield: Industrial and Manufacturing Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
OpenAlex ID: W4413878172