Overview

MES integration – between ERP system and machine

Production of the future: automation network without ERP and MES?

In recent years, experts have repeatedly stated that the automation pyramid is being replaced by an automation network. Instead of a strict hierarchy – from the ERP system to the MES, SCADA and PLC to the machine – the individual intelligent devices are loosely organized and take on changing tasks. The individual components are no longer assigned a clear function. There is therefore no longer a defined ERP system or MES. The functions are distributed across the various components of the network.

Not (yet) possible without MES

The idea of an automation network undoubtedly has its charm. After all, a loose network promises far more flexibility than a rigid pyramid can offer. And of course, the idea also fits in with the times, in which a lot revolves around Industry 4.0 and the Internet of Things. However, the automation network is currently a vision that is miles ahead of the reality on company store floors.

For one thing, even the use of MES is still far from standard – even though the importance of manufacturing execution systems and MES integration is being increasingly recognized. And secondly, innovative technologies that are actually coming onto the market more and more are not capable of reliably controlling and monitoring production. In this respect, we believe that the right approach is to first think about MES integration between the ERP system and the machines and systems.
A study by the consulting firm BearingPoint shows just how important MES is. According to the study, 41 percent of respondents believe that the general relevance of MES will increase significantly in the future, while 47 percent believe that its relevance will tend to increase. For half of the study participants, one of the main drivers for investing in an MES was the prospect of bringing production and IT closer together in the context of Industry 4.0.

However, three other reasons were mentioned even more frequently: Controlling and managing production were important for 76 percent, being able to meet regulatory or customer requirements for 62 percent and process and system harmonization for 54 percent. This shows that MES meet current requirements and are also enablers for the future.

ERP system integration succeeds with an MES

The special value of MES lies in the fact that they create a link between the ERP system, i.e. the commercial world, and the machines and systems, i.e. the production world. In this way, the MES ensures vertical integration of the data. For this to work well, the MES integration must be perfectly integrated into the IT architecture. Specifically, the MES must be properly connected to the ERP system. And it must be able to communicate with the various machine and plant technologies in order to ensure proper machine data acquisition or production data acquisition.

In order to answer what this means in concrete terms, it is first worth taking a look at the current and future framework conditions: In the course of the fourth industrial revolution, manufacturing processes are increasingly being digitized end-to-end. This means that, firstly, all factors that influence the production process and, secondly, all influences of the production process on other factors must be processed directly and routed to their respective destinations. For example, the specifications resulting from a customer order must be transmitted to the manufacturing machine. The machine then uses sensors to continuously monitor whether the order is being carried out correctly. If not, the faulty parts are sorted out as rejects. Finally, the data collected during the production process is reported back and assigned a batch or serial number to ensure traceability.

Exchange of data at all levels of production

At the same time, the number of relevant business objects is constantly increasing. In the past, only the production order was transmitted from the ERP system to the MES – today, communication also takes place directly with the machine. Maintenance definitions and supplier information, serialization data and process parameters or information on quality aspects are also exchanged – and much more. Accordingly, data must be collected from many more individual sources at the commercial level and on the store floor, which requires successful vertical integration of the MES.

MES integration enables bidirectional data exchange

This has consequences for the MES: as the system is responsible for bringing the two worlds together, it must be able to provide numerous interfaces, accept data in very different formats and convert it into a format that can be understood by the entire company. Only in this way can the data be used for other applications.

It is also important that the MES ensures a bidirectional exchange. In the past, information was usually transferred from the ERP system to the MES. Data flowed from the machines to the MES in the opposite direction. Continuous communication from the ERP system via MES to the machine and back again was difficult – also due to the usually very heterogeneous machine park. However, if processes are to be digitized end-to-end, an unhindered network-like data flow in all directions and therefore complete MES integration is essential.

To achieve this, open systems and standards in communication technologies are absolutely essential. Companies must take action from two sides: They should only purchase new machines and systems from suppliers that provide open and standardized access to their data. And they should equip existing equipment with additional technology where necessary in order to keep it up to date.