Best practice-based MES strategy & global implementation for a Tier 1 automotive supplier

Situation

The client is a Tier 1 automotive supplier with a fragmented landscape of manufacturing systems, driven by multiple acquisitions. Several systems were approaching end-of-life, and the factories operated a range of IT applications that were not integrated with the existing ERP system.

Infosys Consulting was engaged to develop a global strategy for legacy MES (manufacturing execution system) migration, multi-site harmonization, and to deliver a phased roadmap for implementation across plants in EMEA, the Americas, and APAC.

Solution

• Conducted a global MES maturity assessment.
• Established a core team and subject matter experts to perform an in-depth analysis of manufacturing processes.
• Harmonized and standardized master data within the ERP system.
• Selected four pilot plants based on diversity of manufacturing processes and suitability for rapid replication.
• Adopted an agile methodology using a sprint framework, with task delivery managed via Kanban boards and executed by an offshore development team.

Benefits

• Standardized global template and persona-based reporting.
• Transparent benchmarking across plants through comparable KPI reporting.
• Cost center allocation to assets during idle time.
• Reliable, real-time production data.
• 5% reduction in non-conformance costs through improved inbound goods tracking.
• 8% increase in machinery utilization.
• Early detection of deviations in machine process parameters.
• Elimination of paper-based work instructions.