Leading Tyre Manufacturer Transforms Shop Floor with MES & Industry 4.0 Digitalization

Delivering Multi-Functionality MES for a Rockwell Automation Implementation

QAS leveraged its manufacturing and technology expertise to deliver a Manufacturing Execution System (MES) solution with multiple functionalities for Rockwell Automation, supporting their MES implementation and ongoing support for a leading tyre manufacturer in India. As one of the country's major tyre production facilities, the client needed a system capable of unifying data across mixing, extrusion, building, curing, and finishing operations — stages that, without a connected MES, typically run as isolated silos with limited cross-visibility for plant leadership.

A Complex, Multi-Module Scope

The engagement required coordinated delivery across 13 distinct MES functional areas — from Master Data Configuration to Warehouse Operations — demanding deep expertise across both manufacturing domain knowledge and Rockwell's technology stack. Each functional area carried its own data model, its own integration touchpoints with the client's existing systems, and its own set of shop-floor stakeholders to align with, making sequencing and dependency management as critical as the technical build itself.

Coordinating Across a Live Production Environment

Because the client's tyre manufacturing lines were operating continuously, the MES rollout had to be planned and executed without disrupting ongoing production — meaning every functional module needed careful staging, testing in parallel environments, and phased go-live windows rather than a single disruptive cutover.

13 Core MES Functionalities Delivered

The solution covered the full MES functionality wheel: Master Data Configuration, Recipe Management, Report Management, Order Management, Order Execution, KPI Efficiency, Energy Management, Warehouse Operations, Genealogy Management, Data Collection Interface, Quality Management, Enterprise Integration, and Dispatch Operation. Together, these modules gave the client a single, connected view from raw material intake through to finished-goods dispatch — replacing a series of disconnected manual processes and standalone spreadsheets.

Built on a Proven Rockwell Automation Technology Stack

The implementation was built using JAVA/J2EE, FTPC (Rockwell), SQL/FTTM, Vantage Point, RS Logix 5000, Kepware OPC Client, and Link Master — giving the client a smart manufacturing backbone fully aligned with Rockwell's ecosystem. This technology alignment meant the MES could communicate natively with the client's existing PLC and automation infrastructure, minimizing the need for custom middleware and reducing long-term maintenance overhead.

Dedicated Team, Long-Term Engagement

A team of 10 to 15 QAS engineers was deployed across onsite and offshore delivery models, sustaining a partnership with the client that has continued for over 5 years. This extended tenure reflects not a single implementation project, but an ongoing relationship spanning initial rollout, functional expansion, production support, and continuous enhancement as the client's manufacturing operations evolved.

Structured for Long-Term Support, Not Just Go-Live

Beyond the initial build, QAS structured the engagement to include ongoing MES support — meaning the client had continuous access to the same team that understood the system's architecture, rather than handing off to a disconnected support function after launch. This continuity has been a key factor in the relationship's longevity.