- Detroit
- Automotive Manufacturing
- 36 weeks
- B2B
- Java, Spring Framework, MySQL, Angular, Docker, Kubernetes, Kafka
Project Brief
A well-known producer of automotive components aimed to enhance overall efficiency, optimise production processes, and streamline operations by replacing their antiquated, disjointed production management systems with a custom manufacturing software development.
Client Background
Operating several manufacturing lines with intricate procedures and a wide-ranging supplier network, the firm was a vital supplier to prominent vehicle manufacturers. Due to their outdated systems’ lack of real-time production data visibility, there were delays, bottlenecks, and quality problems.
Key Challenges:
Solution:
1. Discovery and Planning
We started a comprehensive evaluation of the manufacturer's IT environment, data architecture, and manufacturing procedures. To gather needs and understand pain areas, we conducted workshops and interviews with key stakeholders, such as production managers, engineers, and IT professionals. We created a thorough project roadmap with the MES's scope, technology stack, and implementation schedule specified based on this research.
2. Development
Our experienced team of manufacturing software developers used the Spring Framework and the Java programming language to create a reliable and expandable MES backend. Because of MySQL's dependability and efficiency, we used it as the database. For the frontend development, Angular was used as it offered a contemporary and intuitive interface. Additionally, we put Kubernetes and Docker containers into practice to efficiently deploy and manage the MES across several production environments. Kafka was utilised for system integration and real-time data streaming.
3. Implementation
To implement the MES throughout the manufacturer's manufacturing facilities, we collaborated closely with their IT department. This required moving data from outdated systems, setting up the MES to work with the unique procedures of the business, and giving users thorough training.
Tools & Technology Used
Java
Programming Language
Spring Framework
Backend
Angular
Frontend
Docker
Containerization
Kubernetes
Orchestration
Features:
Production Planning and Scheduling
Considering labour resources, machine capacity, and material availability, the MES offers a centralised platform for developing and overseeing production plans. This reduces downtime and enables optimised production planning.
Real-time Production Monitoring
A live picture of production status, machine utilisation, and quality indicators is provided by the MES, which gathers data in real-time from shop floor equipment and sensors. This makes it possible to make proactive decisions and react quickly to any problems.
Real-Time Performance Tracking
Through interactive dashboards and visualisations, users can effortlessly monitor their portfolio performance, including returns, asset allocation, and historical data.
Quality Management
By monitoring quality indicators, spotting flaws, and overseeing remedial measures, the MES helps with quality control. In order to keep an eye on process variances and guarantee constant product quality, it also offers statistical process control, or SPC.
Traceability
Throughout the production process, goods and materials may be fully traced thanks to the MES. Root cause analysis, quality assurance, and regulatory compliance all depend on this.