Case Study - Portfolio
MOM & MES Implementation at Tier 1 Automotive Component Vendor
Industry: Tier 1 Automotive Component Supplier
Location: Bangalore, India
Project Overview
The company that is the subject of this case study is a Tier 1 Automotive component supplier with the factory located at Bangalore, India. The company decided to implement an MES/MOM system to modernize their manufacturing operations. The main objectives of this project were to enhance operational efficiency, improve product quality, and achieve a just-in-time production model.
Manufacturing Operations Management (MOM)
- Automate the Order Receiving process to be 100% error proof.
- Automate Production Scheduling for a JIT basis, reducing finished goods inventory.
- Ensure 100% product quality with automatic verification.
- Error-proof line side replenishment to avoid material-related downtime.
- Improve overall inventory accuracy with automatic production and shipment reporting.
- Improve delivery performance to the OEM customer.
Manufacturing Execution System (MES)
- Improve product quality and reduce wastage with in-station quality control.
- Record component, process, and audit trace data accurately.
- Accurately capture all downtime instances with reason codes.
- Track key production parameters such as OEE, Hourly Production, and RFT.
- Collect defect, rework, and process data for historical analysis.
Why HelmApps?
After evaluating several vendors, the company selected HelmApps to construct a complete IT solution for the shop floor.
- Comprehensive Solution Stack: HelmApps JITS (MOM) + Easy Manufacturing (MES) provided a solution with all required functionalities.
- Open Standards: Both systems are developed using open standards, allowing for easy integration with the company's existing tools and systems.
- Domain Expertise: The HelmApps implementation team displayed excellent knowledge of the manufacturing domain and the automotive vertical.
- Local Team: The India-based team facilitated smooth communication and collaboration.
- Comprehensive Support: A robust post-go-live support offering included 24/7 assistance and proactive monitoring.
Solution Description
The company implemented JIT Sequencing (JITS) and Easy Manufacturing (MES) from HelmApps, which work together seamlessly. The solution also integrated with the company’s existing QAD ERP system and incorporated open-source tools like Grafana for real-time KPIs and Power BI for analytics.
JITS (MOM) Functionalityxt Here
- EDI Receiving & Validation
- Production Scheduling
- Production Labeling
- Line Side Replenishment Error Proofing
- Quality & Trace Data Verification
- Production & Shipment Reporting
Easy Manufacturing (MES)
- Process Control & SCADA
- Process & Component Trace Data Collection
- In-Station Poka Yokes
- Defect & Downtime Reporting
- Process Deviation Tracking
Implementation & Results
The customer has remarked that the IT eco system that has been built is a global benchmark for their supplier base.
7.3
Months to Completion
0
Budget Overshoot
100%
Objectives Met
The project, led by the HelmApps Implementation team using an Agile Methodology with DEVOPS, was a resounding success. All objectives were met, and the functionality of the system was greatly appreciated by the OEM customer. The project concluded in 7.3 months with no budget overruns.