Manufacturing Execution System in SAP ERP

top MES

Manufacturing Execution System in SAP ERP

With top MES, the SAP ERP solution for manufacturing execution

  • you integrate production into your SAP ERP.
  • you depict manufacturing in real time, create transparency and therefore the basis for Industry 4.0.
  • all SAP data and functions are available on the shop floor.
  • complex subsystems become superfluous

Manufacturing execution has now become an established component of IT portfolios in modern manufacturing and assembling companies. Within the framework of Industry 4.0, MES gains great importance as a data centre, as it creates transparency and thus supports modern production.

But what exactly is MES?

At the functional level, the definitions are as varied as the suppliers and the manufacturing industry sectors themselves, as well as the individual requirements of each and every customer.

The problem with conventional MES architectures

In many cases, MES solutions are extremely differentiated and complex, even if you, as the customer and user, only want to take advantage of a specific combination of functions from the entire offer. This is because conventional MES architectures have one central problem: in order to fulfil their tasks, they need to automatically manage all data and are therefore largely dependent on central ERP systems. The result is redundant data in completely different systems, which has to be synchronised with ERP using complex interfaces.

But MES can also be smart!

Like all products from top flow GmbH, the top MES solution is completely integrated into SAP. That means it is not a separate system but rather an application that seamlessly dovetails into the functions and data of the SAP ERP system.

SAP ERP already supplies an MES with many basic pillars and central functions. top MES takes direct advantage of the existing data and functions and expands them with specific functionality.

Stocks, orders, deadlines, batches, status, documents, persons, machines, tools or capacities, just to name a few important objects, are and remain exclusively administered within the SAP ERP system. Because it has no interfaces, top MES has direct access and, conversely, creates SAP documents for all relevant MES events and results.

The result:

  • No redundancy
  • True data
  • In real time


Production Data Collection (PDC)

The top MES Production Data Collection

  • Works fully integrated in SAP ERP.
  • Provides intuitive dialogue to the production person, also for purely touchscreen operation.
  • Offers a large range of different standards, from simple order progress up to the most extensive status management.
  • Represents the value-creation progress at any detail level.
  • Manages and calculates all performance parameters of a production process.
  • Integrates data and functions from all relevant SAP areas.
  • Posts all results online in the form of SAP documentation.
  • Prepares all data for further processing and analysis.

 

 

Production Data Collection (PDC)

 

Production data collection occupies a central role in MES. On the one hand, it is the worker’s user interface for all manual processes and functions and, on the other, it implements all business logic.

top MES provides comprehensive functionality for production data collection and is completely integrated into SAP ERP without any interfaces.

Examples:

  • Depicts the actual production situation.
  • Records the production progress
  • Registers production problems /errors
  • Posts component consumption and production volumes
  • Documents use of operating material
  • Visualises and checks quality requirements
  • Provides documentation
  • Calculates productivity and costs
  • … to name just a few subjects

In the process, SAP ERP not only supports classic manufacturing orders of discrete manufacturing but all types of orders or scenarios in which SAP systems can be used for carrying out production logistics. Scenarios on project-related manufacturing through networks are also depicted as well as those related to maintenance or service procedures. Series production with product cost collectors as well as the use of internal orders.

With the top MES PDC functions

  • you can create an up-to-date depiction of production in SAP ERP.
  • you integrate the production seamlessly and digitally into company processes.
  • you can compare the planned data with the actual data.

Machine data collection (MDC)

The top MES open architecture

  • flexibly integrates technologies for machine data collection.
  • automates reporting work.
  • reduces the costs of data collection.
  • significantly increases the precision of the information.
  • builds on transparent and open standards.
  • puts an end to priority solutions.

Machine data collection (MDC)

 

In its basic form, machine data collection stands for automatically saving and further processing of information that exists on systems and machines. Its significance has been transformed and extended from one-way processing to the universal information hub between the greatest number of different objects and systems since well before the Industry 4.0 Initiative. The focus is now on integrating all elements relevant to the production process. There may be different motivations for MDC scenarios:

Precise information!

The accuracy of data and results and therefore its quality may be improved substantially compared with manual collection, often mapping the actual situation 100%.

Information variety!

Automated processing enables the examination to be extended to the greatest variety of data. Process parameters should be mentioned above all here, which document the production process and quality, for example, but also machine and system information that could indicate wear and prompt preventative maintenance.

Information quickly!

Only if information is provided in real time it is possible to react quickly and promptly. The effectiveness of production processes that cannot or are not monitored continuously or accurately enough by people are particularly dependent upon MDC.

Cost-effective information!

Automatic processing of machine and system data significantly increases the accuracy, variety and speed while reducing or even eliminating manual input. This is not essential, but is very beneficial in many cases.

The communication methods in automation and control technology have been largely standardised in recent times. As a result, open, transparent and flexibly extendable solutions are used today in place of the previously extremely proprietary constructions.

top MES integrates these solutions bidirectionally into the data flow and processing process, thereby creating a continuous chain of open industrial standards from machine control right through to the SAP ERP system.

Overall Equipment Effectiveness (OEE)

OEE is the central key figure for measuring, analysing and increasing machine and system productivity. In the process, it delivers values that are both comprehensible and able to be influenced.

OEE places the added value of a resource as the central focus. Precise monitoring of time taken, speed realised and the quality achieved is carried out during this process.

The OEE module developed by top flow

  • delivers the basis for efficiency gains through revealing losses.
  • contains all the essential key figures for evaluating and optimising the manufacturing processes.
  • is completely integrated into SAP ERP.

Overall Equipment Effectiveness (OEE)

The term Overall Equipment Effectiveness (OEE) describes the key figure created by the Japan Institute of Plant Maintenance. It is one of the results of the ten-year-long development of the TPM concept (Total Productive Maintenance). OEE is the central key figure for measuring, analysing and increasing machine and system productivity. In the process, it delivers values that are both comprehensible and able to be influenced.

OEE places the added value of a resource as the central focus. Precise monitoring of time taken, speed realised and the quality achieved is carried out during this process.

Losses are taxing and compromise work performance. That is why it is necessary to identify and eliminate them.

Unlike other key figures, OEE does not focus on what has been achieved but rather on what has not been achieved, thus creating transparency. This transparency makes it possible to uncover any existing potential for improvement.

The OEE module integrated into top MES does not require any additional technology – neither for data management nor for analysis. This is an approach that is completely integrated into the SAP ERP system. The completion confirmation data of the SAP system are analysed, and all OEE-relevant information is determined and calculated. Data retention of the OEE key figures as well as their original value are available in a processed form. It is possible for users to carry out flexible and highly productive OEE analyses at a later point in time.

Thus, complete functionality is available already for ERP customers. Alternative technologies such as SAP BI or BO can also be used.

This facilitates fast and efficient decision-making. The specified improvement measures can be quickly checked. The increase in the OEE key figure is the result of the successful elimination of losses.