The manufacturing sector has entered a phase of intense competition, with companies placing premium importance on factors such as Quality, Cost, Efficiency, and Automation. Because of its scale of operations, these factors are crucial for Original Equipment Manufacturers (OEMs).
One of the world's leading manufacturers of passenger, commercial, and defense vehicles, Mahindra Automotive Manufacturing, continually seeks avenues for enhancing its production workflows. One of its recent challenges involved implementing a highly agile and user-friendly Manufacturing Execution System (MES) specifically designed for its Press shop within its four-wheel passenger vehicle manufacturing plants. This system needed to be adept at navigating the intricacies and unique challenges inherent in their manufacturing processes.
Despite the solutions provided by Global MES system providers, it did not completely meet the requirements of Mahindra
Process Change: Global MES system providers aimed to alter Mahindra's press shop manufacturing processes to accommodate their software systems. Mahindra insisted on the vendor software adapting to its existing processes.
Limited Planning Scope: Global MES vendors' solutions lacked support for precise microplanning; they only provided a high-level production plan.
High Acquisition and Operational Costs:
Global system providers imposed exorbitant license fees and demanded extensive customization efforts, leading to high operational expenses.
Monitoring in Real Time: The lack of real-time monitoring made it more difficult to identify production status, machine delays, and breakdowns in an industry where every second mattered. Without rapid data, timely intervention was difficult.
MindNerves' Approach: Designing a Comprehensive MES System
MindNerves here leveraged its experience of 10 years in ERP and production Planning to develop an MES system that met Mahindra's specific requirements.
Shift-wise production plan without the need for manual planning
With MindNerves' solution, Mahindra's production plans analysis experienced a paradigm shift. The configuration offered was as follows:
30-day Demand Analysis: Monthly vehicle demand can be analyzed from business data to build an accurate aggregate production plan for every SKU of every vehicle model.
Daily Shift-wise Production Plan Generation: Granular plans can be created for each shift and each press shop machine.
Real-time Monitoring of Production and Machine Health: Connectivity with PLC through OPC/UA ensures efficient and robust real-time monitoring, providing visibility of machine status at the Press Shop Head level.
Operator Dashboards and Leadership Dashboards: These dashboards facilitate easier supervision and intervention across the entire operations, enabling well-informed decisions.
Breakdown Analysis of Machines by Easily Tagging Root Causes: The system allows for precise breakdown analysis, identifying root causes effortlessly.
Accurate Evaluation of Overall Equipment Efficiency (OEE): The solution ensures an accurate assessment of OEE.
The Effect: Enhancing Press Shop Performance
The Press Shop at Mahindra experienced revolutionary changes as a result of MindNerves' MES solution, which met the obstacles head-on and produced measurable results.
Increased Production and Efficiency: By automating the planning process, MindNerves greatly decreased manual errors and increased production floor productivity. The system's capacity to modify the production plan in real-time guaranteed maximum effectiveness and regular achievement of production goals.
Cost-benefit analysis: The MES system minimized waste and reduced holding costs by optimizing inventory levels. A crucial component, predictive analytics, helped to modify production plans and save needless expenses related to stockouts or overstocking.
Better Communication and Coordination: This software improved communication and coordination within the team.
Integration Across Departments: Improved data flow and communication were made possible by a smooth integration with other departments, particularly the raw materials department.
Cross-Departmental Alignment: Better communication made a coordinated effort, especially within the raw material department, which increased productivity all around.
Making Well-Informed Decisions: Decision-makers were able to make well-informed decisions because of real-time data and analytics access. Comprehensive production performance reports made it easier to make data-driven decisions for continuing enhancements, which in turn improved operations over time.
The Press Shop at Mahindra, which used MindNerves' MES technology, is an example of how advanced manufacturing execution systems can support the industry's transition.