Ashok Leyland, an Indian automobile manufacturer, has successfully implemented its Manufacturing Process Assurance System (MPAS) to transform its manufacturing operations. MPAS is an Industry 4.0 solution that connects over 1,200 machines across 27 assembly lines nationwide, ensuring real-time monitoring and predictive analytics for precision, efficiency, and quality control.
The system is built on a seamless integration of OT (Operational Technology) with IT, enabling real-time tracking of production processes and equipment health. This helps to ensure complete traceability of parts, error-proof assembly, and dynamic work instructions for operators. By implementing MPAS, Ashok Leyland has been able to prevent costly rework, optimize vehicle recalls, and save 75 additional shifts.
The results of the project have been transformative, with significant improvements in efficiency and quality. The system has also HR-driven the company to implement a cultural shift, embedding digital innovation at the core of its manufacturing DNA. By joining the Industry 4.0 revolution, Ashok Leyland has set a new benchmark for digital-driven excellence in the automotive industry.