Quadruple Automation Services
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Industries Automotive Manufacturing
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Automotive Manufacturing
Solutions

QAS delivers MES, PLC/SCADA, ERP integration and AI analytics purpose-built for automotive manufacturing — body shop, assembly, paint, chassis and EV lines, with 24/7 onsite and remote support.

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Body Shop Automation
Assembly Line MES
SAP PP / QM Integration
OEE & Takt Monitoring
Weld & Torque Traceability
Andon & Escalation
IATF 16949 Aware
24/7 Onsite Support
Industry Challenges

What Automotive Plants Face Every Day

Automotive manufacturing operates under the tightest tolerances, the most demanding OEM customer requirements and the most unforgiving takt-time pressures of any industry. A single line stoppage costs thousands per minute. We understand that — and we build systems that prevent it.

Unplanned line stoppages costing thousands per minute
No real-time traceability for OEM audit readiness
Paper-based work instructions causing assembly errors
Manual torque and weld records with no automatic validation
SAP production confirmations hours behind actual production
Legacy PLCs with no network connectivity or diagnostics
Reactive maintenance on critical press and weld equipment
Siloed quality data with no root-cause correlation
Line Stoppage Cost
High cost per minute of downtime
OEM Audit Failure
Recall risk & financial penalty
Manual Entry Errors
1–3% transaction error rate
Reactive Maintenance
40–60% of downtime preventable
Paper Quality Records
Days late to detect escape
ERP Data Lag
2–8 hr reporting delay
Our Solutions

What We Build for Automotive Plants

End-to-end automation and digitalisation capabilities, all delivered from a single experienced partner

Automotive MES

Purpose-built MES for automotive lines — production order management, station-by-station traceability, OEE tracking, takt-time monitoring and andon escalation from body shop to final assembly.

Production Order Mgmt Station Traceability OEE per Line Takt Monitoring Andon & Escalation Shift Reporting
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PLC & SCADA / HMI

Siemens, Allen-Bradley and Beckhoff PLC programming for press lines, weld cells, conveyor systems and assembly tooling. SCADA/HMI design with alarm management and historian integration.

Siemens / Allen-Bradley Robot Integration Weld & Press Control SCADA / HMI Design Alarm Management Historian Setup
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ERP Integration (SAP)

Bidirectional SAP PP, MM, QM and PM integration with your shop-floor MES and SCADA. Production confirmations, goods movements, quality notifications and PM orders flow automatically — no manual entry.

SAP PP Production Orders MM Goods Movements QM Notifications PM Work Orders Batch Traceability Real-time Sync
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IIoT & Machine Connectivity

Connect every robot, press, conveyor, weld gun and test station to your data platform via OPC-UA, MQTT and proprietary protocols. Real-time signal monitoring with edge processing at line speed.

Robot & Press Data OPC-UA / MQTT Edge Computing Real-time Signals Protocol Bridging Cloud Connectivity
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Quality & Traceability

Electronic torque, weld SPC, dimensional data collection and serial/batch genealogy from raw material to shipped vehicle. Full OEM audit trail — any part, any time, any station.

Torque Verification Weld SPC Dimensional Data Serial Genealogy OEM Audit Trail Quality Gates
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AI Analytics & Predictive

Predictive maintenance on press, weld and conveyor equipment. AI quality prediction on weld spots, torque anomalies and dimensional outliers. OEE dashboards updated in real time across all lines.

Predictive Maintenance Weld Quality AI OEE Dashboards Downtime Forecasting Anomaly Detection Shift Analytics
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Functionalities Covered

Every Function, Covered

A full catalogue of automotive-specific manufacturing functions we have designed, built and deployed in production environments

Production Management

Production order download from SAP
Work order scheduling & sequencing
Station-by-station dispatch
Takt time monitoring & alerting
Shift & line OEE calculation
Scrap & rework recording
Changeover time tracking
Production count vs plan

Quality & Inspection

Electronic work instructions
In-process quality checks
Torque wrench data capture
Weld SPC (Cp/Cpk live)
Dimensional measurement import
Leak & end-of-line test results
Non-conformance workflow
OEM PPAP documentation

Traceability & Genealogy

Vehicle / body serial tracking
Component serialisation
Sub-assembly genealogy tree
Barcode / RFID / DMC scanning
Batch & lot traceability
Full part history recall
OEM audit report generation
Label printing & verification

Maintenance & Asset

Predictive maintenance alerts
PM scheduling & work orders
Breakdown recording & RCA
MTTR / MTBF tracking
Spare parts management
Equipment downtime Pareto
SAP PM notification auto-raise
Maintenance KPI dashboards

Machine & Robot Connectivity

Siemens S7 / TIA Portal
Allen-Bradley ControlLogix
Fanuc / KUKA robot signals
Weld controller data (Bosch/Fronius)
Press force & tonnage capture
Conveyor & transfer speed
Vision system integration
Test bench data acquisition

ERP & System Integration

SAP PP production confirmation
SAP MM goods issue / receipt
SAP QM usage decisions
SAP PM work order update
CO cost centre posting
BOM & routing synchronisation
Inventory consumption real-time
Customer portal data feeds

Reporting & Analytics

Real-time OEE dashboards
Shift production summaries
Quality trend charts (SPC)
Downtime Pareto analysis
First-time quality rate
Management KPI packs (auto)
Custom Power BI / Grafana
AI predictive quality reports

Standards & Compliance

IATF 16949 process awareness
AIAG FMEA alignment
Customer-specific requirements
Electronic batch records
Change control & versioning
User access & audit trail
Digital signature support
Recall & containment workflow

Ready to Transform Your Automotive Plant?

From a single line upgrade to a full plant digitalisation programme — talk to our automotive specialists and get a tailored proposal with ROI estimates.

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