Industry 4.0 in the automotive sector
A manufacturer of steel and aluminum components for the automotive industry, supplying major international OEMs. The production facility operates with high operational intensity and large order volumes. The project covered a comprehensive transformation of production, logistics, and reporting processes.

Business challenges

In response to growing customer demands and pressure on efficiency and quality, the company faced the following challenges:

  • Integration with CNC laser cutting machines
  • Lack of digital workflow for technological documentation
  • Manual planning and assignment of production tasks
  • Difficulties in real-time monitoring of order execution
  • Need for more effective reporting of labor and material consumption
  • High amount of waste and recurring process errors

Scope of implementation and transformation

Digital production management module
A module was designed and implemented to manage the entire production process – from planning to reporting. All technological documentation was digitized and made available to employees via intuitive touchscreen terminals, eliminating paper documents and shortening the onboarding time for new workers.

Operator terminals with access to documentation and orders
Workstations were equipped with terminals providing up-to-date information on orders, production parameters, and operation visualizations. Employees can confirm task completion, enter material consumption and waste data, and view operation histories.

MES module – operational reporting and efficiency analysis
MES applications enable continuous monitoring of operations. Progress is automatically recorded in the system, providing a basis for generating labor performance reports. Additionally, the system analyzes operation times to detect bottlenecks and inefficiencies.

Integration with laser cutting machines and nesting software
The production system was integrated with nesting software and CNC machines, allowing direct import of cutting files and assignment to specific production orders. Operators input the number of produced parts and defects, which continuously updates quality reports.

WMS module – production and warehouse logistics
The integrated warehouse system records material inflows and outflows at every production stage. It enables real-time control of semi-finished goods inventory, supports optimal production planning, and accelerates operational decision-making.

Business outcomes

increase in operational efficiency
0 %

by eliminating spreadsheets and manual documents, automating reporting, and visualizing data

reduction in defects and production errors
10 %

through real-time quality monitoring and deviation cause analysis

time savings on administrative tasks
60 %

by shortening production preparation cycles and eliminating data duplication and paper documentation

Industry
Automotive
Processes
flexible production linesprocess automationprocess digitalizationsmart factoryWMS
Processes
flexible production linesprocess automationprocess digitalizationsmart factoryWMS

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