MES for Automotive Manufacturing

YOUR MARGIN IS DECIDED IN SECONDS.
MEASURE EVERY ONE.

At a million parts a year, small losses add up fast. Capture every cycle, stoppage, and scrap event to reduce waste, understand true cost per piece, and prove capacity for the next program. An MES built for scale.
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AUTOMOTIVE SUPPLIERS RUNNING ON MACHINEMETRICS
THE PROBLEM

PRODUCTION LOSSES GROW WITH VOLUME.

Two seconds of cycle drift, a point of scrap, or ten minutes of downtime barely registers on one part. Across millions, those losses add up fast. Today's automotive manufacturers need to measure performance during the shift and correct drift before it happens, not after.

YOU CAN’T RUN HIGH VOLUME PRODUCTION ON END OF SHIFT DATA.

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MES BUILT FOR THE ASSEMBLY PLANT

In a machining cell the equipment sets the pace, and the platforms with automotive heritage were never taught what a tool change, a setup, or a program revision is.
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ERP STANDARDS AS TRUTH

The routing records what was reported, not what ran. When the standard drifted three programs ago, every cost per piece, capacity model, and quote built on it inherits the same error and repeats it.
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The stopwatch doesn't scale

Time studies, sampling, and shift-end batch confirmations fail twice at automotive rates. You can't stop production ten times a shift and you can't defend a number a person had to remember.

EVERY LOSS HAS A COST.
NOW YOU CAN PROVE IT.

Built for Tier 1 and Tier 2 suppliers, MaximaOS turns live production data into real time execution that keeps high volume, tight tolerance work on schedule and shipments complete.

Measure every cycle, not a sample.

Track actual cycle time by part, operation, machine, and shift, including micro stoppages. Set Parts Goal thresholds to catch operations falling behind during the shift and correct drift before it erodes margin across the program.
See OEE and production analytics
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Rank downtime by what it costs.

Capture every stoppage as it happens, classify it by cause and duration, and rank losses by Pareto. Convert downtime into lost production value, measure changeovers against plan, and put a dollar value behind capital requests and price negotiations.
See downtime tracking
Downtime Hero

One suspect part, not a full bin.

Detect tool wear, chipping, and breakage from load behavior in real time. Catch process drift before it creates out of spec parts, hold feed when needed, and protect lights out production from turning one failing tool into a bin of scrap.
See tool life management
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Attribute scrap where it happens.

Capture scrap at the source and tie it to the machine, job, part, operator, and shift. Send verified records to ERP, contain quality events with production data, and pinpoint causes faster without relying on guesswork.
See quality and scrap reduction
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Clear the gate on demonstrated data.

Prove capacity from demonstrated equipment performance and compare it against loaded demand. Use actual cycle times for run at rate, capacity verification, and new line launches, replacing assumptions with production evidence from day one.
See capacity and quoting
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Cost per piece, built from actuals.

Build job cost from actual labor, machine time, and production quantities. Trace margin variance to the operation and standard that missed, measure improvements against baseline, and give customer cost targets production data they can stand on.
See labor tracking and costing
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See It In Action

Tuffaloy runs a six-machine Swiss cell across three shifts with one machinist on all six. Off shifts were reporting good parts and quietly leaving scrap out of the count. Once the machines started counting for themselves, inventory corrections fell 85% year over year. SIX MACHINES. ONE MACHINIST. NO GUESSING.

TESTIMONIALS

PROOF FROM PLANTS WITH THE SAME PHYSICS.

High-volume machining, thin off shifts, one operator across six spindles, and an ERP that only ever knew what somebody typed into it.
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ALMOST ANOTHER SHIFT, FREE.

After implementing MachineMetrics, we saw between a 10-15% improvement in overall uptime and, on top of that, a 15-20% efficiency gain. Since we run four shifts, that's the equivalent of almost another shift for free.

- Michael Wisnefsky, Engineering Manager

20% MORE UTILIZATION. NO NEW MACHINES.

A 20% increase in utilization across all machine assets, quantified conservatively, with outsourced production brought back in-house and machine purchases deferred.

 

85% FEWER INVENTORY CORRECTIONS.

An 85% year-over-year reduction in inventory corrections. Ten hours per machine per month reclaimed from manual bar loading, which funded automatic bar loaders and opened the door to lights-out running.

KEEP EXPLORING TEAMS

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industrial

INDUSTRIAL EQUIPMENT

One measurement framework across the footprint, deep enough that each plant runs on it.
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contract manufacturers

CONTRACT MANUFACTURING

Cost per job on actuals, across whatever mix the customer sends.
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Medical

MEDICAL DEVICE

Tight tolerances at volume, with a production record built as the parts are made.
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firearms

FIREARMS

High-volume precision on a mixed fleet, measured automatically rather than sampled.
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WHAT IS THE EXECUTION GAP COSTING YOU?

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Manufacturing ROI Calculator | What the Execution Gap Costs You

See what production gaps cost you in overtime, scrap, tooling, and maintenance, and how fast a modern MES pays for itself. Instant results.

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How Tuffaloy Closed the Execution Gap on Epicor

Better Data, Better Decisions: How Tuffaloy Closed the Execution Gap on Epicor

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We Went to ProveIt! to Challenge a Popular Belief. Here's What Happened.

MachineMetrics CEO Bill Bither went to ProveIt! 2026 to challenge the idea that manufacturers have to build their MES from scratch. Here's what he proved.

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Automotive Manufacturing Challenges and IoT Solutions

Automotive manufacturers are turning to the Industrial IoT, among other Industry 4.0 solutions, to solve these complex problems.

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THE NEXT PRICE-DOWN IS
ALREADY SCHEDULED.

Connect a sample of machines and see what your plant is actually producing — and what the gap is costing you per part.

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