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

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.