Leveraging MES Integration for Operational Excellence in A ‎Green Field Automotive Stamping Plant: A Digital Transformation ‎Case Study

  • Authors

    • Piyush Dipak Bachhav Student, Second Year M. Tech.: Project Management, Department of Manufacturing Engineering and Industrial Management, COEP ‎Technological University (COEP Tech), Chhatrapati Shivajinagar, Pune: 411005, Maharashtra State, India
    • Sudhir Madhav Patil Associate Professor, Department of Manufacturing Engineering and Industrial Management, COEP Technological University (COEP ‎Tech), Chhatrapati Shivajinagar, Pune: 411005, Maharashtra State, India
    • Mitesh Shashikant Jadhav Mahindra Accelo Ltd., Worli, Mumbai: 400018, Maharashtra State, India
    • Harsh Dilip Kene Student, Second Year M. Tech.: Mechatronics, Department of Manufacturing Engineering and Industrial Management, COEP Tech-nological University (COEP Tech), Chhatrapati Shivajinagar, Pune: 411005, Maharashtra State, India
    https://doi.org/10.14419/033gde10

    Received date: July 14, 2025

    Accepted date: August 20, 2025

    Published date: August 31, 2025

  • Automotive Stamping; Digital Manufacturing; Green Field Deployment; Manufacturing Execution System; MES Implementation; OEE; Smart ‎Factory; Tandem Press Line.

  • 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.

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  • How to Cite

    Bachhav, P. D. . ., Patil, S. M., Jadhav , M. S. ., & Kene, H. D. . (2025). Leveraging MES Integration for Operational Excellence in A ‎Green Field Automotive Stamping Plant: A Digital Transformation ‎Case Study. International Journal of Basic and Applied Sciences, 14(4), 808-817. https://doi.org/10.14419/033gde10