In the context of rapid changes in the automotive industry, the transition to electrification, the rise of intelligent systems, and evolving environmental regulations have created a dual challenge for parts suppliers. They must not only meet the needs of the traditional internal combustion engine market but also adapt to the growing demand for electric vehicles (EVs). At the same time, increased market competition has raised customer expectations regarding the quality, delivery times, and cost control of parts. These pressures are driving suppliers to improve production efficiency through technological innovation and lean manufacturing to remain competitive.
Overview of MAHLE
MAHLE is a century-old company with a rich history and a strong spirit of innovation, committed to providing pioneering solutions for greener and more efficient transportation. Globally, one in every two vehicles is equipped with MAHLE’s technology.
As a leader among global automotive parts suppliers, MAHLE Group recognizes the critical role that digitalization plays in the industry’s development. Years ago, MAHLE integrated digital solutions into its core strategy for parts production and services to consistently deliver high-quality products and services.
Project Background
MAHLE’s filtration system, a key link in the automotive supply chain, provides essential parts to automakers around the world, including engine air filters, oil filters, fuel filters, and activated carbon canisters.
However, the factories producing these filtration systems still relied heavily on paper records and manual operations, resulting in inefficient information storage and retrieval, as well as increased operational risk. With the expansion of production scale and complexity, along with the industry’s push towards digitalization, MAHLE’s filtration system factories faced several challenges:
1. Data Silos: Production data from different factories was stored in separate systems, lacking unified management and analysis, making cross-factory information sharing difficult.
2. Complex Quality Traceability: Traditional paper records could not meet the demand for rapid traceability, making it time-consuming to identify quality issues during production, which delayed response times to customers.
3. Delayed OEE Monitoring: The existing Overall Equipment Effectiveness (OEE) data was manually recorded, making it impossible to reflect equipment status in real time, hindering production efficiency improvements.
4. Lack of Process Optimization Tools: Factories lacked real-time monitoring and analysis tools for bottleneck processes, preventing continuous optimization.
5. Insufficient Equipment Management: Equipment maintenance relied on experience and manual judgment. Deteriorating equipment conditions were not detected in time, leading to frequent unplanned downtime.
The Solution: Comprehensive Digital Transformation
To address these multifaceted challenges, LinkedData implemented a Manufacturing Execution System (MES) for MAHLE, providing a comprehensive digital solution aimed at building a unified, transparent, and scalable production management platform. This implementation covered core modules such as personnel management, quality traceability, equipment monitoring, production line efficiency improvement, and material management. By enabling seamless integration between equipment and systems, LinkedData optimized the entire production chain.
Key Technical Highlights
Equipment Data Integration and Reverse Control
The LinkedData MES system was deeply integrated with over 20 production lines across three MAHLE factories, enabling real-time data collection from injection molding, welding, assembly, and other equipment. This ensured transparency in the production process. The system also employed reverse control functions to implement deep error prevention at the equipment level.
Full Lifecycle Traceability Management
LinkedData’s traceability module provided end-to-end traceability across material batches, processes, work-in-progress, and finished products. This ensured strict quality control at every step, enhancing product stability and reliability. When quality issues arose, the system quickly enabled precise traceability and isolation of affected batches, improving response efficiency.
Real-time OEE Monitoring and Bottleneck Analysis
The OEE module of the MES system collected and calculated equipment operation data in real time, offering management a panoramic view of production efficiency and aiding in continuous production line optimization.
Predictive Maintenance and Equipment Management
By monitoring equipment operation data in real time, the system anticipated maintenance needs, reducing the risk of unplanned downtime and ensuring uninterrupted production.
Electronic Display Boards and Paperless Management
Following the implementation, the factories gradually transitioned to paperless management for key processes such as daily production reports, operation manuals, and inspection records. Electronic display boards provided real-time production line status updates, allowing managers to quickly respond to issues on the floor and shorten decision-making chains.
Since 2021, the gradual implementation of LinkedData’s MES system across MAHLE’s filtration system factories, from Shanghai to Tianjin and Guangzhou, has resulted in significant operational improvements. Through collaboration with LinkedData, MAHLE has made important strides in smart manufacturing, enabling it to effectively respond to the rapid changes in the automotive industry and achieve sustainable growth.
MAHLE believes that one of the core competitive strengths of future automotive parts suppliers lies in optimizing product performance, enhancing quality, streamlining supply chain processes, and creating additional value-added services. At every stage of service, suppliers must meet or even exceed customer expectations. As LinkedData’s digital solutions continue to take root, MAHLE’s achievements in smart manufacturing will further solidify its leading position in the industry. LinkedData will continue to work alongside MAHLE to drive the digital transformation of the automotive parts industry.
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