The Problem
A major automotive manufacturing and component assembly unit supplying high-precision assemblies to Tier 1 OEM lines struggled with shop floor visibility blind spots, manual shift handovers, and paper-based quality inspection checklists. OEE calculations were lagging by days, and compiling complete component traceability chains for customer quality audits required up to 3 days of manual file searches across paper batch registers.
The Implementation
Deployed Micraft MES and WMS across active manufacturing lines with direct PLC/OPC-UA machine connectivity, barcode-guided operator terminals at each workstation, real-time OEE telemetry dashboards, and automated Poka-Yoke quality gates synchronized directly with enterprise SAP ERP.
The Outcomes
- 28% increase in overall shop floor visibility with real-time bottleneck alerts
- Machine OEE improved from 71% to 86% within the first 6 months of rollout
- 100% digital component traceability with instantaneous serial, lot, and heat number search
- Customer audit compliance time reduced from 3 days to under 30 minutes
- Zero dispatch mix-ups with barcode-assisted Poka-Yoke packing validation
"Micraft MES and WMS gave our plant management complete real-time control over assembly lines and warehouse bins, ensuring zero dispatch errors and instant audit readiness."
— General Manager - Operations & Supply Chain, Tata AutoComp
