Overview

HENGSTENBERG – Production at a glance: MES ensures real-time monitoring

When the previous production data acquisition system threatened to become a stumbling block for strategic business digitization projects, the food manufacturer Hengstenberg took the decisive step: With top MES the long-established family business opted for a solution integrated into the SAP system that would bring the production process into the future in terms of technology and functionality.

Sauerkraut and red cabbage belong on the German menu – that sounds like a cliché from decades gone by. And indeed, there were years when young buyers in particular were unfamiliar with everything that was considered typical German cuisine. However, it is hard to imagine modern cuisine without the fine sour preserves and the trend towards using traditional, good products is benefiting the tried and tested classics. Market leader Hengstenberg from Esslingen in Swabia is one of the main beneficiaries of this trend. Under the brands Mildessa, KNAX, STiCKSi and Altmeister, the family business offers a diverse range of cabbage products, vinegar, pickles, vegetable and delicatessen specialties.

Production processes in the harvest cycle

Hengstenberg produces the entire range of around 140 different items at two locations in Baden-Württemberg and Hesse. The production processes change over the course of the year for a large number of different production orders and the permanent workforce is supplemented by seasonal workers. This is because the agricultural raw materials have to be processed according to the harvest cycle. The production lines used for this are extremely complex. Depending on the production order, they include systems for sorting and washing the various raw materials, transport systems, filling machines, blanchers and stoves as well as packaging systems and palletizers.

In order to make production at both sites more transparent, Hengstenberg introduced a production data acquisition (PDA) system years ago. This was connected to the SAP ERP and HR systems via interfaces. However, the solution did not meet the requirements in many respects, as the IT project manager at Bad Friedrichshall, Thushyanthan Nadarasa, recalls: “A major disadvantage was the time-delayed transmission of the recorded data to the SAP system. We had to check messages in the PDC system, process them manually and then transfer them to the ERP system via interfaces. This made it almost impossible to compare actual and planned values in real time and key figures such as overall equipment effectiveness (OEE) could only be calculated using manually created Excel lists.”

Legacy system is a brake on digitization

Further effort was required to continuously adapt the PDA solution to the production sites, as the two plants have different production focuses with correspondingly different requirements for production data collection. Over time, two partially individualized solutions developed on the basis of one PDA software. As a result, Hengstenberg’s IT department had to carry out a great deal of maintenance work, redundant interfaces to the overarching systems were required and master data had to be managed twice.

“As part of a detailed IT strategy, we worked on the deep digitalization of our production. But our old PDA system was neither suitable for the necessary expansions nor functionally up to date,” says IT Manager Gerd Pfeiffer.

Business strategy planning was an important driver for more digitalization and automation: Some additional products and smaller batches were to be introduced, as well as the possibility of implementing more custom production. The resulting complexity could not be handled with the existing PDA, its interfaces, manual checks and approvals, media disruptions and inconsistent reporting.

SAP integration and customizable design

Together with the plant managers, IT therefore planned to introduce a new store floor data collection system that would also meet future requirements. An important element of this future viability was the interaction with the SAP environment – including full support for S/4HANA. Gerd Pfeiffer: “We soon came across top MES from top flow. Its seamless integration and support of SAP standards was a clear plus. With a solution that delivers this “out of the box”, we would make a huge leap forward in terms of digitalization.” The aim was end-to-end communication with the ERP system, for standardized and up-to-date operating data: From vinegar production to washing and blanching the vegetables; from canning to filling and packaging; from attendance and order times to ancillary activities, faults and maintenance.

Hengstenberg also opted for top MES from top flow because of the customizable worker user interface. It was important to replicate parts of the operating logic of the old PDA so that seasonal staff or employees who change their work location at short notice can get started without any training. “From the preliminary discussions and planning through to implementation, the project has thrived to this day thanks to the flexible software and the high level of consulting expertise of the topflow team,” concludes the project team. “And the collaboration was also perfect in terms of adherence to deadlines and costs.” The basis for the project’s success was the agile approach and intensive coordination with the department heads. This allowed the MES system to be introduced optimally for very different production processes – aligned with the fixed harvesting and production cycles.

 

Automated postings as a basis for reporting

The advantages of the new MES solution were already apparent during the first partial commissioning: for example, the modern touch terminals allow employees to automatically log on to production orders via RFID chip – including defined authorization concepts. If required, a user can complete several tasks at the same time and record them together with their break times. The system is able to differentiate between production-related times and ancillary activities such as cleaning or retooling the machines. All data is available to external reporting tools and time management in HR management.

The configurable operator interface provides logged-in users with the functions they need in a uniform and clear dialog – even when process-specific special logic is running in the background. The intuitive user guidance eliminates the need for time-consuming training, even when employees switch from vinegar filling to cabbage filling, for example. “We involved our colleagues and specialist departments in the project at a very early stage and incorporated their ideas. The benefits of the new PDA system become apparent as soon as you start using it. This can be seen in the user-friendly interface, the extended range of functions and the flexible setting options,” says project manager Markus Hägele.

Investment in optimized processes

Overall, Hengstenberg benefits in particular from the seamless SAP integration of top MES: firstly, because – unlike before – employees can book all production orders in real time and automatically. The countless manual and error-prone transfers to SAP are completely eliminated. Secondly, because the new solution offers significant process improvements. Thanks to the comprehensive machine connection to top MES, bookings are made online and processes are automated. The integration of maintenance is also planned: Repair orders will then be generated live and automatically via top MES based on the fault. The technician records his repair time and provides feedback directly on site in SAP.

At Hengstenberg, the investment in top MES is seen as a significant contribution to the digitalization strategy: the solution is ready for the important S/4HANA changeover, many simplifications in everyday life accelerate the production process and the IT department concentrates on one modern system – instead of keeping two variants functional. The conclusion of those involved is correspondingly positive:

“top MES enables us to optimally monitor and evaluate the production status and offers company-wide standardized OEE evaluations of availability, performance and quality of production. The project gives us transparency and traceability in all areas!”

Success Story top MES Hengstenberg



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Overview