AUTOMOTIVE AND TRANSPORTATION
MG Motor India
Products
MindSphere, Tecnomatix
Business challenges
Visualize near real time
performance parameters
to determine
machine productivity
Identify main factors contribut-
ing to bottlenecks that are
dynamic and change over time
Find effective ways to consider
all relevant constraints in a
complex environment to carry
out root cause analytics
Keys to success
Use the MindSphere
visualization application
to create customized
performance dashboards
Create a closed-loop digital
model to understand the root
cause of a problem by simulat-
ing the production using the
actual production data
Resolve identified issues
and implement the changes
to the production system
with confidence
Results
Increased throughput by
15 percent in paint shop
Identified root cause of
production loss with IoT
data analytics
Optimized production process
by leveraging advanced IoT
data analytics
Automotive manufacturer increases throughput by 15 percent
in paint shop
MGI uses MindSphere and Plant needed enhanced analytics to eliminate
Simulation IoT data analytics to identify process bottlenecks.
the root cause of production loss
“The existing system did not provide the
Addressing the bottlenecks in paint time needed to execute individual steps
shop operations at each station such as wait, travel and
idle time and they couldn’t capture the
In 1924, Morris Garages vehicles was
founded in the United Kingdom (UK). process time and store it retrospectively.
MG Motor India (MGI) is a subsidiary We needed solution to fulfill the challenge
and manage reliable accurate input data,”
of SAIC Motor Corporation Limited and
specializes in automotive manufacturing. says Ravi Mittal, director of manufacturing
Most operations are located primarily in for MG Motor India.
India at their plant in Halol. The company
manufactures automotive parts and
vehicles. There are many moving parts
in an automotive assembly line, including
a paint shop that focuses on surface
treatments to the body of the vehicle and
pre-treatment and electrolytic deposition
(PTED) stations.
Streamlining PTED paint shop procedures
has been a significant bottleneck for the
MGI plant team over the past few years.
With legacy automation systems in opera-
tion for over 20 years, the team couldn’t
use existing system such as programmable
logic controllers (PLCs) and Andon Systems
to disclose or suggest information on
productivity development prospects.
They couldn’t study processes aside from
standard key performance indicators (KPIs)
such as overall equipment effectiveness
(OEE) or downtime data. The systems in
the paint shop did not provide reliable and
accurate real-time performance data.
While they were able to pluck the
low-hanging fruit using the existing
methods and technologies, the team
siemens.com/software
“We use the dashboard’s color
feature to indicate whether
important parameters such
as JPH, cycle time, waiting
and travel time stay
within their target
operating efficiencies.”
Ravi Mittal
Director of Manufacturing
MG Motor India

Leveraging MindSphere to connect Using the out-of-the-box (OOTB)

the data and identify bottlenecks
To address this issue, MGI adopted
MindSphere®, the industrial IoT as a
service solution from Siemens Digital
Industries Software, and Plant Simulation
in the Tecnomatix® portfolio. MindSphere
and Plant Simulation are part of the
Siemens Xcelerator portfolio, the compre-
hensive and integrated portfolio of
software, hardware and services. MGI
adopted these two software portfolios
successfully resulting in increased through-
out and production in PTED line.
MindSphere connectivity solution enabled
MGI’s team to connect isolated assets and
transfer the data to MindSphere using
mobile communications (GSM) network.
All timeseries data from each step of
production process were uploaded into
MindSphere to provide the basis for further
data analysis.
“We use the MindSphere application,
Visual Flow Creator, to build our workflow
to create rules, define KPIs and perform
advanced analytics. It enables us to
convert the raw timeseries data into
meaningful information,” says Mittal.

We use the MindSphere application, Visual Flow

Creator, to build our workflow to create rules,
define KPIs and perform advanced analytics.
It enables us to convert the raw timeseries
data into meaningful information.”
Ravi Mittal
Director of Manufacturing
MG Motor India
“We are pleased to partner “Using another MindSphere application,
with Siemens and we aim to easyDASH, enables us to create dashboards
adopt software technology easily. We can monitor and visualize shop
throughout the general floor assets for optimization and perfor-
assembly to further trans- mance management,” says Mittal.
form operations.” “We use the dashboard’s color feature to
indicate whether important parameters
Ravi Mittal such as JPH, cycle time, waiting and travel
Director of Manufacturing time stay within their target operating
MG Motor India efficiencies. This provides us with a more
cohesive vision of the current state of
process and allows us to make more
effective decisions.”
Visualization and customized analytics
powered by MindSphere capture the digital
process data for micro steps and even
storing it on the cloud. This enables MGI
to visualize and carry out strengths, weak-
nesses, opportunities and threats (SWOT)
analysis of the process. This helps the MGI
team identify the root causes of the pro-
duction losses and actions to improve the
net output.
Integrating MindSphere and Plant
Simulation to optimize production
throughout
“Once we collect real production data from
the shop floor, we transfer the timeseries
data from MindSphere to Plant Simulation,
which enables us to use a digital twin
model to understand the root cause of a
problem by replaying the production using
the actual production data,“ says Mittal.
“Once we identify the problem, we make
the required changes and verify the impact
of the changes using the simulation with
the actual production data, which more
accurately shows any unintended effects or
new constraints caused by these changes.
After resolving these issues in virtual digi-
tal twin model, we now have confidence to
implement the changes to the production
system.”
Solutions/Services
MindSphere
siemens.com/mindsphere
Tecnomatix
siemens.com/tecnomatix
Customer’s primary business
MG Motor India has a clear
vision to build the next gener-
ation automotive company,
while delivering the best auto-
motive experience for
customers – one that reflects
the Morris Garage heritage
and sporting legacy.
https://www.mgmotor.co.in/
Using the industrial internet of things
(IIoT) paired with plant simulation forms
the closed-loop comprehensive digital
twin, which enables MGI to use real
production data to continuously
optimize throughout.
Improving paint shop performance
“Siemens has the ability to combine three
domains: operational technology, IIoT
technology and system simulation all
connected in near real time, which helps
us increase throughout in PTED line
by 15 percent,” says Mittal.
Collaborating with Siemens to continue
the digital transformation journey
“MGI is constantly evolving to meet
rapidly changing requirements and
provide innovative services by collaborat-
ing with ecosystem partners,” says Mittal.
“Our collaboration with Siemens is focused
on industrial digitalization and intelligent
manufacturing. With MindSphere, we hope
to boost productivity and improve produc-
tion efficiency by leveraging advanced IoT
data analytics to quickly monitor essential
assets and systems in real-time and
minimize unexpected downtime. We are
pleased to partner with Siemens and we
aim to adopt software technology through-
out the general assembly to further
transform operations.”

Customer location
Gujarat
India

Using another MindSphere application,

easyDASH, enables us to create dashboards
easily. We can monitor and visualize
shop floor assets for optimization and
performance management.”
Ravi Mittal
Director of Manufacturing
MG Motor India

Siemens Digital Industries Software

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