Frequently Asked Questions
General Questions
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Production control is the interface between incoming orders and production. It ensures that the right products are manufactured in the right quantity at the right time and in the right place, as cost-effectively as possible.
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A Manufacturing Execution System (MES) is a manufacturing management system that maps, monitors, and controls complex manufacturing processes.
The main objective of an MES is to ensure the effective execution of manufacturing operations and improve production performance. It helps a company achieve these goals by collecting and processing accurate, real-time data throughout the entire production lifecycle.
Functionally, the acronym MES, which stands for Manufacturing Execution System, describes automated systems that manage, document, and synchronize the execution of real-time physical processes involved in transforming raw materials into intermediate or finished products. The goal is to use MES control and functionality to achieve greater efficiency in product execution and production.
Manufacturing Execution Systems do much more than control hardware. They also deal with quality, inventory, and other important parts of the manufacturing process, aspects that are typically addressed by incorporating these processes through MES software.
These extensions are not readily categorized as part of traditional MESs. Instead, many analysts in the MES industry refer to them as manufacturing operations management solutions, or MOM. Whatever the jargon, MES software works to report data, provide accurate information about what’s happening on the shop floor, and make manufacturing processes less difficult. Below are some of the important functionalities of an MES system. These include machine data acquisition (MDI), store floor data collection (SFDC), performance analysis, detailed scheduling, traceabilit,y and document management.
Shopfloor Apps
AC4DC – Next-Gen Shopfloor Connectivity
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AC4DC stands for “Asset Connectivity for Data Collection”. In other words, “connecting machines to collect data”. The term “asset” is the generic term for machines, sensors or manual workstation components that are to be digitally connected.
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AC4DC offers 4 main improvements for customers:
- A more stable and resilient data supply. This is achieved because data collection can be made fail-safe via small and cost-effective hardware, and seemingly lost data can be recovered quickly.
- Increased data sovereignty and cybersecurity. This is achieved because data streams can be encrypted more easily than with other solutions. This also improves data integrity.
- Fast and flexible implementation of connectivity. This is achieved through standardized templates and central control via a control center. Plug-and-play compatibility minimizes installation and maintenance effort.
- Fast scalability of the connection. This is achieved through the cloud. The solution is also adaptable to a wide range of applications. The signal interpretation complies with the IEC standard, which reduces the need for retraining.
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With AC4DC, FORCAM ENISCO offers a completely new generation of software. The solution is based on so-called microservices, works with Kubernetes, and runs on the smallest industrial PCs.
Microservices are comparable to Lego building blocks that can be combined and expanded into ever-new shapes, like standardized containers. Kubernetes is the platform that recognizes and assembles the combined containers and starts the respective programs.
Containerized software in the smallest hardware brings great advantages for cost efficiency, data sovereignty and data security. Overall, users can significantly increase flexibility and reliability in production with AC4DC.
Functionalities
Production monitoring
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Production monitoring is like conducting an orchestra: just as a conductor directs the interaction of many musicians and their instruments, production monitoring ensures transparent and efficient control of all processes in production.
The task of production monitoring is complex. Many factors play a role – the product itself, market requirements, legal regulations. Various components such as detailed planning, visualization, data collection, energy monitoring and production control are therefore crucial.
Production control
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Production control is the interface between incoming orders and production. It ensures that the right products are manufactured in the right quantity at the right time and in the right place – as cost-effectively as possible.
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The increasing complexity of markets, the growing individualization of products and increasing competitive pressure are constantly posing new challenges for production management:
- Globalization and digitalization:manufacturing networks must be increasingly globally and digitally networked.
- Individualization and batch size:Customers want ever more individualized products, which leads to smaller batch sizes and a greater number of variants.
- Sustainability:The reduction of resource consumption and emissions is becoming increasingly important in the industry as a result of sustainability reporting obligations.
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The choice of the right production control method depends on various factors – such as company size, strategic goals, product portfolio and production environment.
Centralized production control
All decisions and planning are made at a central location in order to save costs. Centralized production control also enables a high level of transparency and control over the entire process. This method is suitable for companies with a manageable product portfolio and stable production conditions.
Digital production control
Digital production control is essential for companies on their way to becoming a smart factory. By using digital technologies, companies can make their production processes far more efficient, flexible and transparent.
Kanban production control
With the Kanban principle, production is controlled by the requirements of the subsequent production stage. Signal cards – “kanban” in Japanese – trigger replenishment as soon as a certain material stock level is reached. This avoids overproduction and high stock levels. The Kanban method is characterized by simplicity and efficiency.
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With the help of modern software solutions from FORCAM ENISCO or SAP Digital Manufacturing that can be implemented in ERP systems, production processes can be planned and controlled efficiently. In order to categorize different production strategies and processes that are necessary for efficient production, a distinction is made between three factory types according to the number of product variants manufactured (Source: McKinsey):
- One-off production:Production of unique items according to customer requirements (e.g. ships, bridges). The processes usually involve long throughput times, require highly qualified employees and generally result in high production costs.
- Series production:Production of a certain number of almost identical products in series (e.g. cars, computers, furniture). The processes are usually semi-automated and require shorter throughput times than individual production.
- Mass production:Production of large quantities of identical products over a long period of time (e.g. screws, food or products in the chemical or electrical industries). The processes are usually highly automated and the production costs per unit are comparatively low.
Visualization and reporting
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In simple terms, visualization means putting the collected data into a “visible” form – for example as clear diagrams, graphics or with interactive real-time dashboards. Instead of confusing columns of figures, you get a clear picture of production or the entire company and can see trends, correlations and anomalies at a glance, making it easier to share information across teams.
With Digital Manufacturing, both the MES solutions SAP Digital Manufacturing and MES FLEX from FORCAM ENISCO can be used to achieve complete transparency of your production and thus optimize the workflow.
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The key figures used to create a report can come from various sources and form the “data feed” for SAP Digital Manufacturing and MES FLEX, which control, monitor and optimize production processes in real time.
- Content Reporting
- Reporting by target group
- Reporting by frequency
- Reporting according to objectives
Personnel time recording
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Personnel time recording is the systematic recording of employees’ working hours in a company. It is used to obtain a precise overview of the hours worked by individual employees and thus to enable more accurate corporate planning – whether working hours, personnel requirements or financial planning through a precise calculation of unit costs.
In the past, time recording was usually done manually, e.g. by filling in timesheets. However, this is an inaccurate, error-prone and above all time-consuming process, especially when it comes to subsequent evaluation.
In contrast, the introduction of digital, automated personnel time recording is much more advantageous.
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Basically, all working times must be recorded. This means that both the total working time and the duration of rest breaks must be systematically documented. This obligation arises from the Working Hours Act in Germany and serves to protect employees.
- Start and end of daily working hours: The start and end of each working day must be recorded. This also applies to flexible working time models.
- Overtime: Any work performed in excess of the agreed working hours must be recorded. This also includes short-term overruns of the working day.
- Working on Sundays and public holidays is generally prohibited. Exceptions must be documented by the employer and the hours worked recorded.
- Night work: The hours worked at night must also be recorded separately.
- Rest breaks and rest periods: Compliance with the legally prescribed rest breaks and rest periods must be ensured and documented by the working time recording system.
Track and Trace
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Traceability describes the ability to document the life cycle of a product or information from its origin to the current point in time (and vice versa) in a traceable manner. Where do the raw materials and individual parts of a product come from? Which production facilities and machines were involved in the manufacturing process? Put simply, it is about being able to precisely answer the questions “Where does it come from?” and “Where does it go?”.
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Traditionally, traceability in production areas is done by manual documentation or recording. However, this method is very error-prone and time-consuming.
The use of digital traceability systems is much more efficient. The specific implementation of a traceability system depends on the respective area of application. Basically, digital traceability is based on the following elements:
- Unique identification: each object, component or piece of information is provided with a unique identifier – e.g. serial number, batch number, barcode.
- Documentation: All relevant information along the life cycle is recorded and documented – e.g. production data, transportation routes, storage conditions.
- Linking: The collected data is linked together to enable continuous traceability.
- Database: The information is stored in a database and can be retrieved and analyzed as required.
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Traceability systems offer numerous advantages. A few points should be considered before implementation in order to find exactly the right solution.
- Analysis: Before introducing and operating a traceability application, a risk and cost/benefit analysis should be carried out – costs for required hardware, software and personnel in relation to the desired goals and possible risks.
- Complexity: The choice of a traceability system should be proportionate to the complexity of the tasks, especially in complex supply chains.
- Data protection and security: The storage and processing of sensitive data in the context of traceability requires a high level of data protection and security.
- Standardization: Standardized interfaces for the integration of a traceability system enable the exchange of data between different systems and companies.
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The implementation of traceability offers companies numerous advantages:
Maximum transparency: All steps in the life cycle of a product are clearly and comprehensibly documented. This includes the entire supply chain.
Improved quality assurance: By tracing products, processes or information, sources of error can be identified and rectified more quickly. This enables targeted quality control and improvement.
Efficient risk management: In the event of problems, traceability enables the affected area to be narrowed down quickly and precisely. Negative effects such as product liability risks can be minimized by acting quickly, e.g. through product recalls.
Optimized processes: The analysis of information from traceability helps companies to optimize processes and make them more efficient.
Increased trust: Transparent traceability systems create trust with customers and business partners as they ensure the traceability and safety of products and processes
Compliance with legal regulations: In many industries, traceability is required by law, e.g. in the food industry or in the field of medical products.
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The increasing digital networking of companies and systems facilitates comprehensive and efficient traceability across company and national borders. By exchanging data, all players within a supply chain can access information in real time and thus react more quickly and effectively to events.
Digitization also enables efficient and cost-effective implementation of track and trace tools. The integration of artificial intelligence (AI) is playing an increasingly important role in event-driven data collection.
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Event-driven or event-based data acquisition in production means that data is not recorded at fixed intervals, but only when a relevant event occurs. This could be the start or stop of a machine, the change of a parameter or the achievement of a certain quality criterion, for example. The advantages are reduced data traffic, lower resource consumption such as computing power, more flexible scalability, improved data quality and ultimately optimized business processes.
Energy monitoring
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The term energy monitoring refers to the systematic recording, analysis and evaluation of energy consumption. The aim is to create transparency about the energy flow, uncover potential savings and sustainably increase energy and resource efficiency. In the context of rising energy prices and the need to reduce the ecological footprint as well as to comply with regulatory requirements – e.g. when publishing sustainability reports – the topic of energy monitoring is becoming increasingly important.
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Cost reduction: monitoring and therefore implementing improvement measures to reduce energy consumption leads to lower energy costs and increases the company’s competitiveness.
Sustainability: Efficient use of resources is crucial for reducing the ecological footprint and achieving sustainability goals.
Transparency: The primary goal is to obtain a detailed overview of energy consumption in production. This includes recording data on electricity, gas, water, compressed air and other energy sources used in production processes.
Identification of potential savings: By integrating energy data into an MES, production processes can be optimized in terms of their energy consumption and bottlenecks can be avoided. This enables targeted energy-saving measures, e.g. the optimization of machine parameters, the replacement of outdated technology or the implementation of more energy-efficient technologies.
Improved energy management: The data obtained forms the basis for strategic energy management. Companies can make well-founded decisions to optimize their energy consumption in the long term and future-proof their energy supply.
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The implementation of an energy monitoring system usually takes place in several steps: First, the specific objectives of the energy monitoring system must be determined and the requirements for the system defined. Then all relevant measuring points in the production process at which energy consumption is to be recorded must be identified, sensors and meters at the installed measuring points record the energy consumption and transmit the data to a central system, such as MES solutions from FORCAM ENISCO (E-MES, MES FLEX) or the SAP Digital Manufacturing System for resource efficiency and energy monitoring. The data collected is collated, analyzed and visualized in the form of clear graphics and reports. Based on the analysis results, specific measures to increase energy efficiency can be derived and implemented.
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Energy monitoring can be used in almost all production sectors, e.g:
- Metal processing: monitoring the energy consumption of furnaces, presses, welding systems
- Plastics processing: analysis of the energy requirements of injection molding machines, extruders
- Food industry: optimization of energy use in cooling systems, baking ovens, packaging machines
- Chemical industry: monitoring the energy consumption of reactors, pumps, compressors
- Paper industry: analyzing the energy requirements of paper machines, dryers
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Energy monitoring is becoming increasingly important for companies in view of the increasing reporting obligations and regulations relating to sustainability and social responsibility, for example in the area of
1) CO2 reduction
Energy monitoring enables energy consumption to be recorded and analyzed, allowing potential savings to be identified and reduction measures to be verified. The documentation of energy consumption and the savings achieved are becoming a central component of sustainability reporting.
2) Social governance and sustainability reports
Investors and other stakeholders are increasingly demanding transparency with regard to environmental, social and governance (ESG) criteria. Energy monitoring provides measurable data and helps companies to demonstrate their sustainability performance. The integration of energy data in sustainability reports strengthens credibility and enables comparison with other companies.
3) Supply Chain Act
The Supply Chain Duty of Care Act (LkSG) obliges companies to respect human rights and environmental standards in their supply chains. Energy monitoring contributes to transparency and traceability in the supply chain by recording the consumption of resources along the value chain. Companies can improve their sustainability performance through energy-efficient production processes and thus meet the requirements of the LkSG.
Advantages of MES systems:
Manufacturing Execution Systems (MES) from FORCAM ENSICO or SAP Digital Manufacturing offer functions for energy monitoring, performance analysis and traceability. Digital recording and evaluation of energy data can facilitate reporting and enable data-based decisions to optimize energy efficiency. Government funding programs support companies in the implementation of energy management systems.
Machine data acquisition
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Digitalization is finding its way into production halls – and machine data acquisition (MDA) plays an important role in this. But what exactly does this term mean? What data is recorded and what are the benefits? We will show you how you can use the MDC solution from FORCAM ENISCO – AC4DC to “shake up” your shop floor and revolutionize the processes in your machinery.
In simple terms, machine data acquisition (MDA) is about collecting information directly from machines and systems and making it available digitally. Instead of laboriously entering data into tables by hand, machine data acquisition records it automatically and in real time. This can be information about production progress, energy consumption, material flow or the condition of the machine itself, for example.
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Machine data can be tapped directly from the control system. There are a variety of providers and different communication protocols. AC4DC converts a status from the signals, e.g. machine is running/not running, and passes this on in the required standard. The standardization (interpretation) of the data is an added value that not every provider can deliver. This means that the interpretation does not have to be made at a later point in time, making it less complex.
Sensors can also be used, but control systems are already present on most machines and a lot of data can already be read from these.
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The range of machine data that can be collected is enormous and naturally depends on the machine in question and the objectives of the data collection. Basically, the data can be divided into different categories:
1) Operating data:
- Production data: Number of parts produced, production speed, scrap rate, running times/downtimes, etc.
- Process data: Temperature, pressure, speed, flow rate, etc.
- Condition data: Vibrations, noise, temperature of components, etc.
2) Energy data:
- Power consumption
- Compressed air consumption
- water consumption
3) Quality data:
- Dimensional accuracy of the products
- Surface quality
- Defect detection
4) Material data:
- Material consumption
- Material flow
- Batch numbers
These are just a few examples of machine data collection to show how many of these parameters can have an impact on productivity and how many ways there are to optimize it based on accurate data collection – and, above all, how important an MDC system can be.
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The continuous recording and evaluation of machine data offers companies enormous optimization potential and competitive advantages:
1) Increased transparency & efficiency
- Real-time insights: machine data acquisition enables seamless monitoring of production processes in real time. This provides a comprehensive overview of the performance of individual machines, the material flow and the overall equipment effectiveness (OEE).
- Optimized production planning: The collected data can be used to better plan production processes and identify and eliminate bottlenecks at an early stage.
- Reduced downtimes: By monitoring the condition of the machine, maintenance work can be planned in advance (predictive maintenance). Unplanned downtimes, which cause high costs, are thus minimized.
2) Increased product quality
- Continuous quality control: by monitoring relevant parameters throughout the production process, deviations from the standard can be detected and corrected at an early stage.
- Seamless traceability: In the event of quality problems, machine data acquisition enables seamless traceability of production data and batches.
3) Reduced costs
- More efficient use of resources: by optimizing production processes and reducing waste, resource consumption (material, energy) is minimized.
- Lower maintenance costs: Predictive maintenance makes it possible to optimize maintenance operations and avoid costly unplanned downtimes.
4) Increased flexibility & scalability
- Rapid response to market changes: Machine data collection enables flexible and agile production that can react quickly to new requirements and market changes.
- Easy scalability: Data collection can be adapted to new machines and systems at any time and expanded flexibly.
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AC4DC from FORCAM ENISCO is a highly available and secure next-generation connectivity solution for production. The cluster- and cloud-enabled MDC tool collects data from machines and makes it available in real time to enable data-based decisions:
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Easy installation and operation
Intuitive user interface and simple configuration processes enable fast commissioning and easy operation.
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Scalability
AC4DC is suitable for production facilities of any size and can scale as the business grows.
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Comprehensive device support
AC4DC supports a wide range of industrial machines and devices. Pre-built drivers and connectors ensure seamless integration.
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Real-time data analysis
AC4DC provides robust real-time data analysis capabilities that enable users to make informed decisions quickly.
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Outstanding support
FORCAM ENISCO provides comprehensive support to ensure users receive knowledgeable and responsive assistance when needed.
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Even faster and more flexible implementation
Standardized templates and a central control point speed up machine connection and rollout.
Stable and uninterrupted data supply
- Fail-safe data collection through cluster technology for stable connectivity
- Fast recovery of data after downtimes
- Compensation for communication failures to other software systems
- Improved data sovereignty and cyber security
- Encrypted data streams for controlled and secure machine data collection
- Cyber-secure design for increased robustness against cyber attacks
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Document management
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Document management describes the efficient and systematic recording, administration, storage, provision and archiving of documents – throughout the entire life cycle of the corresponding product or process. Nowadays, this usually involves digital document management, which includes the use of software solutions and digital archives.
Paperless production is the central goal of digital document management. It enables the transition from paper-based processes to digital workflows and thus forms the foundation for the smart factory.
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Increased efficiency and productivity
- Faster search & retrievability: documents can be retrieved quickly and easily thanks to central storage, metadata and search functions.
- Automated processes: Workflows automate recurring tasks and reduce manual effort, e.g. during approval or invoice verification.
- Improved collaboration: Simultaneous editing, versioning and comment functions facilitate collaboration on documents, even in teams.
Reduced costs
- Reduced paper consumption & storage costs: digitizing documents minimizes paper consumption and costs for storage and archiving.
- Less administrative work: Automated processes and optimized workflows reduce manual administrative work.
- Avoidance of errors & duplication of work: Central data storage and versioning minimize sources of error and avoid duplication of work.
Improved compliance & security
- Compliance with legal requirements: Archiving and deletion deadlines can be met automatically to ensure compliance.
- Control over sensitive data: Access control and authorizations protect sensitive data from unauthorized access.
- Traceability & audit compliance: Version history enables changes to be tracked and ensure audit compliance.
Increased customer satisfaction
- Faster response times: Quick document retrieval and optimized workflows enable faster response times to customer inquiries.
- Improved customer service: Fast access to all relevant information enables better and more efficient customer service.
Detailed scheduling
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Detailed scheduling – also known as detailed production planning – is an essential process of production management and deals with the short-term planning and control of production processes. In contrast to rough-cut planning, which deals with longer-term goals and strategic decisions, detailed planning focuses on the day-to-day and detailed planning and organization of production. The aim of detailed planning is to make optimum use of the resources available for each order, such as machines, materials and personnel, in order to ensure timely and efficient production.
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Detailed planning comprises a variety of tasks that are closely interlinked. These include
1) Ressource planning:
- Machine allocation: Detailed planning of machine allocation, taking into account set-up times, maintenance intervals and capacity limits.
- Personnel deployment planning: Assignment of employees to the individual operations, taking into account qualifications, availability and working time models.
- Material planning: Ensuring material availability for the planned production orders at the right time and in the right quantity.
2) Process planning:
- Sequence planning: determining the optimal sequence of production orders on the individual machines and systems in order to minimize throughput times and avoid idle times.
- Batch size planning: Determining the optimum batch size for the individual production orders, taking set-up costs, storage costs and capacity utilization into account.
- Scheduling: Determination of start and end dates for the individual production orders and work processes, taking into account throughput times, delivery dates and resource availability.
3) Production control:
- Use of order data from the ERP: essential to obtain detailed information about the orders to be produced with target dates and priorities.
- Order release: Release of planned production orders for execution in production.
- Progress control: Monitoring of production progress and identification of deviations from the plan.
- Intervention control: Taking corrective measures in the event of deviations from the plan, e.g. adjusting the sequence planning or prioritizing urgent orders.
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From improved collaboration and communication to increased profitability and customer satisfaction, detailed planning offers numerous benefits that help companies achieve their strategic goals and compete in a dynamic market environment. Significant benefits include:
- Shorter lead times: Minimizing lead times by avoiding idle time and optimized sequencing lead to faster completion of products.
- Lower stock levels: By planning materials in line with demand and avoiding overproduction, stock levels are reduced, and storage costs are lowered.
- Higher capacity utilization: Optimum utilization of production resources leads to higher productivity and profitability.
- On-time delivery: Optimum planning and control of production processes ensures that delivery deadlines are met.
- Increased customer loyalty: Reliable adherence to delivery deadlines strengthens customer loyalty and improves the company’s competitiveness.
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Detailed planning is a complex process that is associated with numerous challenges. Unexpected problems can often arise that require improvisation in planning – e.g. a supplier cancels, an important employee falls ill or an unforeseen cost item arises. Without the necessary transparency and control, it is therefore almost impossible to create up-to-date production plans.
This makes it all the more important to have flexible detailed planning with appropriate digital tools that allow you to run through different scenarios so that you always have a “plan B” at the ready.
The biggest challenges in detailed planning:
- Dynamic environment: short-term changes to customer requirements, material bottlenecks or machine breakdowns require planning to be highly flexible and adaptable.
- Data quality: The quality of planning depends largely on the quality of the underlying data. Inaccurate or incomplete data can lead to planning errors and inefficiencies.
- Complexity: The increasing number of variants, the shortening of product life cycles and the globalization of supply chains increase the overall complexity of production – and therefore also of detailed planning.
Not forgetting the human factor: detailed planning is not just a technical task, but also requires the involvement of employees through continuous exchange and open communication of mutual experience.
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Various methods and tools are available to manage the diverse tasks of detailed planning. These include:
- Gantt charts: Graphical representation of production orders and their schedules.
- Network planning technique: Representation of complex projects with dependencies between the individual operations.
- Priority rules: Definition of rules for sequence planning, e.g. “shortest operation time” or “earliest completion date”.
- Simulation: Simulation of the production system on digital end devices (tablets etc.) to test different planning scenarios and find the optimum solution.
- Software solutions: ERP systems (Enterprise Resource Planning) with integrated modules for detailed planning (e.g. FE Detailed Scheduling or SAP REO).
To cope with the complexity of detailed planning, different systems offer a variety of functions that support detailed planning, e.g.:
- Graphical planning boards: for visualizing the production plan and for interactive planning of production orders.
- Automatic sequence planning: Algorithms that determine the optimum sequence of production orders, taking various criteria into account.
- Material requirements planning: Functions for calculating material requirements and monitoring material availability.
- Capacity planning: Functions for calculating the utilization of machines and personnel to identify bottlenecks.
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In order to fulfill the tasks efficiently, continuous integration of machines, MES and ERP systems are required. Machine data acquisition (MDA) and production data acquisition (PDA) provide the necessary real-time information from production.
With detailed planning tools such as FE Detailed Scheduling from FORCAM ENISCO or SAP REO, you have real-time transparency: production management can view the plan at any time, keep an eye on the production status with all available resources and immediately identify potential bottlenecks and short-term disruptions.
3D visualization
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Visualization means presenting complex information and processes with the help of visual aids in order to make them easy to understand and use. Various media and methods are used that are tailored to the specific requirements of production.
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2D and 3D visualizations play a particularly important role in various areas of manufacturing companies and make a significant contribution to increasing efficiency and quality assurance.
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2D visualization
2D visualizations provide a two-dimensional representation of objects and processes. They are used in the form of:
- Application
- Technical drawings: They form the foundation of manufacturing and precisely define products and components in terms of geometry, dimensions, tolerances and surface finish.
- Circuit diagrams: In electrical engineering and electronics production, circuit diagrams are essential for documenting the wiring of components and the signal flow.
- Flow diagrams: They illustrate complex processes and sequences in production and help to identify bottlenecks and optimization potential.
- Layout planning: 2D floor plans and factory layouts help with the planning of production lines, the arrangement of machines and the optimization of material flows.
- Performance and consumption analyses: 2D charts on machine performance or energy consumption in real time and in time series help factory teams to eliminate recurring deficiencies and make sustainable optimizations.
- Advantages of 2D visualization
- Clarity and precision: 2D illustrations are based on standardized symbols and display formats that are globally understandable and minimize misinterpretation.
- Relatively simple creation: 2D representations can be created and modified with comparatively little effort using CAD programs.
- Low memory requirements: Compared to 3D models, 2D files require significantly less storage space and are easier to manage.
- Challenges of 2D visualization
- Limited spatial imagination: complex components and interrelationships are difficult to visualize comprehensibly in 2D.
- High degree of abstraction: 2D drawings require a certain level of technical understanding and experience in order to correctly interpret the information displayed.
- Limited simulation possibilities: Dynamic processes and movements can only be depicted statically in 2D and require additional explanations.
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3D visualization
3D visualizations offer a realistic, three-dimensional representation of objects and processes and open up new possibilities for manufacturing companies in terms of:
- Application
- Product design and development: 3D models enable the virtual design of products and components. Different design variants can be easily created, compared and simulated for their functionality.
- Virtual commissioning: Entire production plants can be virtually constructed and simulated before real commissioning takes place. This allows planning errors to be identified and rectified at an early stage.
- Robot programming: The programming of industrial robots is simplified and made safer by 3D simulations. Robot movements and gripping processes can be programmed and optimized offline before they are used in the real environment.
- Education and training: 3D models and simulations offer an effective way of training employees on new machines and processes. In this way, the handling of complex systems can be trained safely.
- Advantages of 3D visualization
- Improved spatial understanding: complex geometries and interrelationships can be grasped intuitively using 3D visualizations, facilitating communication between those involved.
- Early detection of errors: By simulating processes and sequences, potential errors and collisions can be identified and rectified as early as the planning phase.
- More efficient processes: Virtual commissioning and robot programming using 3D simulations reduce set-up times and increase productivity.
Improved communication: 3D models and animations enable clear and comprehensible communication, even for non-experts.
- Challenges of 3D visualization
- High effort and costs: creating 3D models and simulations involves more effort and costs than 2D visualization.
- Increased hardware and software requirements: Powerful computers and special software are required to process 3D data.
- Complexity and training: Working with 3D software requires a certain training period and specific specialist knowledge.
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The E-MES shop floor solution from FORCAM ENISCO enables the creation of digital twins of production systems in 2D or 3D. This offers a number of advantages:
Functionality:
- Object creation: visualization is based on 3D objects, which can either be imported from the standard library or created in the object editor itself.
- Scene structure: By preparing objects into scenes, the real production plant can be completely mapped virtually.
- Data linking: The objects are linked with production data to create a real-time model of the plant. For example, material flows, machine statuses and process progress can be visualized.
What are the special features?
- 2D & 3D visualization: In the E-MES solution, it is possible to visualize in both 2D and 3D formats, depending on requirements and needs.
- Product Card App (PCA): The PCA bundles all relevant data for each manufactured product in one app. This ensures access to information on product quality, process analyses, etc. at all times.
Cloud MES
SAP Digital Manufacturing (SAP DM)
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SAP Digital Manufacturing (SAP DM) is a cloud-based solution for Manufacturing Execution Systems (MES) that enables manufacturing companies to monitor and optimize their production processes in real time. It integrates advanced technologies such as IoT and AI to support intelligent, data-driven decisions. Through seamless integration with other SAP solutions, it offers end-to-end process and data integration. This solution helps companies to produce more efficiently and sustainably while responding flexibly to changes in demand.
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The consulting is based on a systemic approach that guides you successfully through every phase of your project, right up to the full implementation of SAP Digital Manufacturing. This also includes empowering all stakeholders.
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As an SAP Silver Partner, we offer direct communication with SAP Digital Manufacturing (SAP DM) with our connectivity solutions. This allows you to connect your machinery (brownfield and greenfield) in record time and gain complete transparency of your production processes. Reliably and securely.
SAP Resource Orchestration (SAP REO)
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SAP Resource Orchestration (SAP REO) uses automation and AI technologies to optimize shift planning in manufacturing and make it more efficient.
Benefits
- Increased production efficiency reduces idle times
- Improved resource utilization avoids bottlenecks and overloads
- Fast response times ensure continuity of production
- Higher product quality reduces errors and maintains standards
- Cost savings through efficient use of resources and less waste
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Yes, plans can be manually customized in SAP Resource Orchestration (SAP REO). This functionality allows users to flexibly accommodate specific requirements and changes in their IT infrastructure. Manual adjustments may be necessary, for example, to react to unexpected events or to carry out customized optimizations.
The manual adjustment of plans can include various aspects, such as changing schedules, assigning resources or modifying workflows. SAP REO offers a user-friendly interface and extensive tools to ensure that adjustments can be made efficiently and effectively.
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SAP DM REO leverages the power of automation and AI technology to optimize shift planning and make it more efficient. This innovative tool helps production managers in manufacturing to identify potential inefficiencies, quickly adapt to unexpected events such as machine or employee breakdowns and prioritize the skills of individual employees to optimize throughput – all while ensuring maximum efficiency.
SAP Digital Manufacturing: Execution
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Optimized workflows and paperless processes.
Benefits
- Real-time transparency across production processes
- Traceability from raw material to end product
- Improved production planning and control
- Increased flexibility and responsiveness
- Optimum resource utilization
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The Production Operator Dashboard (POD) is the main interface between the operator on the shop floor and the application containing the production data.
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Operator guidance in SAP Digital Manufacturing is a powerful tool that ensures that production workers are optimally guided through the manufacturing process. It provides a user-friendly and efficient way to ensure that orders are executed correctly and on time. Here is a description of how this worker guidance works:
Timely notifications of changes
With SAP DM, employees are notified of changes to the order or configuration in a timely manner. This ensures that the latest instructions and requirements are always available and can be implemented immediately. The system sends automatic notifications and updates to employees’ mobile devices so that no information is overlooked.
Clear work instructions
SAP DM provides clear and detailed work instructions that guide you step by step through the production process. These instructions are available directly on employees’ mobile devices, minimizing misunderstandings and errors. The instructions can include text, images and videos to ensure that each step is explained correctly and clearly.
Easy order entry and processing
Employees can easily receive, pick and complete orders via a mobile device. SAP DM makes it possible to manage orders directly on the shop floor without the need for paper documents. With the mobile app, employees can:
- Receive orders and start immediately
- Identify and pick the required materials and tools
- Document and finalize each work step
- Track progress in real time
These functions improve the efficiency and accuracy of order processing and ensure that production runs smoothly and without interruptions.
SAP Digital Manufacturing: Insights
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Identify potential for improvement and increase the efficiency of your processes.
Benefits
- Maximized efficiency and productivity at all production sites
- Optimized processes through precise and harmonized analyses
- Continuous improvement (CIP) based on reliable key figures
- In-depth root cause analysis with comprehensive OEE evaluation
- Detailed loss analysis by material and shift
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- Insights at global and plant level
- KPI analyses
- Overall equipment effectiveness (OEE)
- Design and customize dashboards & reports
- Analysis of shift-based production
On-Premise MES
MES FLEX
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With MES FLEX, we offer manufacturing companies a turnkey and freely expandable platform solution for the era of the Industrial Internet of Things (IIoT). Included in the multi-cloud-enabled solution are.
(a) comprehensive connectivity for the shop floor and top floor, i.e., the connection of heterogeneous machine parks as well as networking with the pot floor (corporate management level),
(b) a semantic production data model as the digital twin of production, and
(c) open web interfaces for free composition and collaboration of in-house and external IT systems.
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With the MES FLEX solution, customers gain full transparency in production, higher efficiency throughout the company, and the greatest possible freedom and flexibility in IT architecture.
- Full transparency on the store floor is achieved through extensive connectivity: machines of different vintages and manufacturers and the ERP level can be easily connected and networked. Plug-ins and templates for various machine types and vintages are used for this purpose.
- Higher efficiency through turnkey usability: companies can start immediately to increase productivity: A high-speed computer creates the digital twin of production. This production data model can be used immediately to increase efficiency with preconfigured MES applications with more than 70 analyses and reporting functions.
- Greatest flexibility for composition and collaboration of IT systems: The solution is freely extensible, and customers can create individual IT architecture with their own and external systems and applications – through the open programming interface FORCE Bridge API. In addition, hybrid infrastructures of edge and cloud computing are possible.
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Connectivity and Digital Twin: Comprehensive connectivity for the shop floor and top floor is ensured by standardized machine plug-ins and ERP adapters. At the heart of the platform are a main memory-based rule engine for business process modeling and real-time data validation. The rule engine contains a semantic data layer that transforms Big Data into Smart Data, and thus generates the digital twin of production virtually on the computer – a central prerequisite for greater transparency and efficiency.
Turnkey MES Apps (Manufacturing Execution System): MES FLEX offers pre-installed MES applications such as tracking (Track & Trace), performance analysis (reports, visualizations, alarms), manufacturing data management (production data, order data, DNC), energy monitoring (overview of all consumption values), detailed planning and control (orders, capacities, dynamic scheduling).
Open web interfaces: Any third-party systems can be integrated via the open programming interface FORCE Bridge API. The FORCE MES FLEX solution offers pre-installed market-leading apps from FORCAM partners, for example, for artificial intelligence (AI), tool data management (TDM), quality assurance (CAQ), and product lifecycle management (PLM).
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Adapters enable bidirectional communication between FORCE MES FLEX and your ERP backend for ERP system integration.
If customers do not have SAP, there is an option for the customer’s ERP system to interact via the open interface. Suppose the ERP vendor does not support our technology. In that case, we can organize XML-based data exchange, which is usually necessary with any ERP system and requires appropriate application development on the ERP side.
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The rule engine is in-memory based with Complex Event Processing (CEP). The combination of in-memory computing and CEP is a unique selling point of FORCAM: It provides the required real-time data processing in milliseconds. Only with in-memory-based data storage, i.e. data storage in main memory, can the speed required for real-time computing be achieved in the range of milliseconds.
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The MES FLEX solution includes the first open web interface for digital manufacturing called FORCE Bridge API. It allows customers and partners to interact with the FORCAM platform via so-called REST APIs freely. FORCAM developed, patented, and publicly published the FORCE Bridge API together with industry and academia in 2018.
With this, FORCAM provides customers and partners with open application-level programming interfaces: Using these REST APIs, customers or partners can retrieve any information from manufacturing via the platform and write corresponding information back to the platform. Access to the FORCAM platform via REST API is license-free, making access barrier-free. If a customer wants to implement the applications themselves and perform the machine connection independently, the FORCAM Academy offers appropriate training.
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FORCAM FORCE Bridge API™ – The Open API for Smart Manufacturing. Below are all the available SDKs and some sample applications.
E-MES
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ENISCO by FORCAM GmbH is a global software company with the goal of making manufacturing smarter, more efficient and more flexible and making the Smart Factory a reality. As a subsidiary of FORCAM GmbH, ENISCO has over 25 years of experience in the development and implementation of Manufacturing Execution Systems (MES), Supervisory Control and Data Acquisition systems (SCADA) and Human Machine Interface solutions (HMI). ENISCO’s software solutions optimize manufacturing operations in a wide range of industries, from water treatment plants, to fully automated logistics centers, to complete automotive paint shops. Currently, ENISCO is represented in Germany, India and China by 50 experts whose passion is to develop new technologies and optimize the manufacturing process of our customers.
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The company’s specialty is the “E-MES” production control system. ENISCO’s modular Manufacturing Execution System offers a customized solution for each customer. The solution networks the factory both horizontally across the entire manufacturing process and vertically across all process levels. Due to its integrated data acquisition, analysis and display, E-MES ensures consistently transparent production and logistics processes and thus forms the basis for any Industrie 4.0 solution.
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In addition to the software, ENISCO offers comprehensive services:
- Analysis and consulting
- Conception and planning
- Custom development
- Comprehensive project management
- On-site integration
- Trainings
- Support
MES LITE
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An MES solution for the manufacturing industry provides a solution that converts all machine signals from the factory into a real-time data model. With it, factory teams can then precisely analyze machine performance states in preconfigured reports on a central dashboard and on all desired computer end devices. This makes the solution an important tool for modern store floor management.
The packages included are predefined and standardized. Machine data and production data acquisition (MDE/BDE) as well as important key figures such as overall equipment effectiveness (OEE) are common.
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MES LITE can be implemented in just a few days. The required hardware is manageable, usually comprising an I/O controller for machine connectivity and an edge gateway as the central interface between the shop floor and the top floor.
Factory teams can digitally connect a wide variety of machines quickly and benefit from the advantages of the solution in a short time: real-time transparency about the performance of the machines as well as higher efficiency through precise analyses and standardized reports – the basis for the data-driven continuous improvement process (CIP).
Consulting
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In today’s fast-paced manufacturing world, efficiency is key. Our innovative MES solutions offer you the tools to optimize your production, reduce costs and prepare your company for global competition. Our experts analyze your individual starting situation and adapt strategies and technologies specifically to your needs. We support you during implementation to ensure a smooth process and provide you with real-time insights into your production data. Together, we will make your smart factory a reality.
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Based on your strategy, we work with you to systematically develop the relevant value chains for your production. Our method for this is called Iterative Process Prototyping (IPP®). In joint workshops, we define a binding target image for your technical requirements. We focus on the necessary analyses of optimization potential and potential risks.
- Analyze the initial situation
We work with you to assess your unique initial situation. Typically, an on-site visit with a shop floor walk takes place in order to identify the fields of action.
- Define fields of action
After the initial analysis and shop floor walk, the fields of action are defined and specific measurable goals are set that are to be achieved with the MES solution (e.g. reduction of downtimes).
- Describe requirements
We describe the technical requirements based on the framework specifications.
- Define the solution
We define and describe the solution system with architecture and interfaces.
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IPP® stands for Iterative Process Prototyping. It is an iterative process for the design and implementation of value-adding processes in production and the company as a whole.
IPP is characterized by the following features:
- Fast results
- Sustainable, quality-assured documentation for management and employees
- Transparency, order, structure and clear assignment of tasks
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The Process Playbook is the result type for presenting the content of Iterative Process Prototyping (IPP®). It is comparable to a navigation system or an atlas, which can be used to navigate from overview representations to ever finer detail. While classic approaches to business process architecture use a large number of different methods, procedures and models, the IPP® Process Playbook is structured in 4 levels with clearly and unambiguously defined symbols, forms of representation and content that are coordinated with each other.
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The IPP® level presentation addresses the different perspectives of the various stakeholders in the company and ensures transparent traceability for managers and employees. As a result, complex business management issues can be made transparent and usable for customers in a simple and intuitive way, but with sufficient scope and integration. The IPP® Process Playbook shows ways from apparent complexity to simplicity and ensures a consistent transition from processes of the individual departments to IT.
The IPP® Process Playbook has its origins in the SAP environment, further information can be found at: www.processplaybook.com
Further questions
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An Ishikawa diagram, also known as a fishbone diagram or cause-and-effect diagram, is an analytical tool used to systematically identify the causes of problems. It helps to categorize these causes, thus improving our understanding of the problem and enabling us to develop solutions.
- An Ishikawa diagram is a tool for identifying and analyzing causes and effects.
- It is also referred to as a cause-and-effect diagram or fishbone diagram.
- It is used to structure complex problems and identify the most important causes.
- Kaoru Ishikawa developed it and is an important part of quality assurance
Other names for it are: fishbone diagram, fault tree diagram, cause-and-effect diagram.
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The fishbone diagram helps you to systematically develop solutions to problems. This method is beneficial when the root causes of errors or waste are unknown.
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You do not know the causes of a problem
This method is helpful when the cause of a problem is unknown. You can systematically identify potential root causes that build the foundation to develop solutions.
You want to include different perspectives
It is often used in group settings and team discussions. Diverse perspectives and expert opinions contribute to a more comprehensive analysis during brainstorming sessions. This collaborative approach helps uncover hidden causes, fosters deeper insights, and promotes a well-rounded problem-solving strategy.
You want to improve processes and products in a targeted way
It is often used in quality improvement processes such as Six Sigma or Total Quality Management (TQM). It helps to identify the major causes of quality issues.
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- Unclear problem definition
- Neglect of relevant categories or causes
- Superficial analysis that does not capture the true causes
- Lack of teamwork and collaboration in the creation
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Tool management ensures that the information of the various tools is managed in a clear framework. A database provides that the tools’ data are stored and linked to a corresponding tool management software. A tool management system is used in production. The software can record different types of data, graphics, etc., of the tools.
The tool management is also responsible for ensuring that the manufacturing process proceeds without errors. Within tool control, a distinction is made between master data and transaction data.
Master data
In computer science and business administration, master data means data of various objects used in the company. This data includes, for example, information about products, employees, suppliers, and customers, which are relevant to the company’s business processes. Master data is stored in various ways, such as in databases or simply as a file. Master data is always static information.
Master data of tools include:
- the geometric functions
- the structure of the tools
- how these tools can be used
Data for the tools include within the master data the tool descriptions and how the devices are to be used by employees and machines. Master data does not have data about the availability of the tools, as this is handled by other software.
Transaction data
Transaction data is often the opposite of master data. In contrast to master data, transaction data is dynamic because it is constantly changing. In terms of a database, transaction data is, for example, customer data. Customer data includes, for example, customer orders and contract data. Transaction data also provides for changes to the inventory in an ERP system.
Available knowledge is considered in the master data. However, this is only possible if data for the respective tasks is available at the employees’ workstations. Tool data can easily be linked to third-party software using the tool management software. This happens either by accessing the database of tool management software or by accessing various interfaces.
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This type of software records and maintains the life cycle of manufacturing equipment. The following factors play a role here:
- Procurement of the toolswith the question at which time the device is needed.
- How are the individual tools assembled into a complete device?
- The type of use:On which machine is which tool used?
- Grinding and disposal of the tool.
The tool management software is also the hub of the various tool data. Data on the product, cutting conditions, and 3D models make work preparation and planning much easier. The transfer of tool data and cutting data to a CAM system is useful for NC programming. Other beneficiaries of the tool management software are the purchasing department, which receives information from the ERP system about the order quantity of the cutting sets, storage systems, production control, and presetting devices.
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Sophisticated tool management software offers several advantages, which are listed below:
- Production resources are used more effectively.
- Capital commitments are avoided.
- Meaningful reports can be created across departments. For example, the purchasing department can use the evaluations to see when certain parts for the tools need to be procured again.
- New tools can be found thanks to the intelligent database search quickly.
- Current recommendations and information from the tool manufacturers are available through the software.
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The complete tools are recorded and managed within the so-called tool list. The printable tool list contains information about the tools’ placement (and thus for picking). In many cases, the tool lists contain further details on the complete devices. These include information for NC programs, plans for clamping and printing, etc. The header data contains information on the unique ID and information on which machine which tool is suitable for. A list containing the tools shows all the complete tools that are required for an operation. This list also includes essential information for the NC program, such as the sequence in which the NC program processes the tools. The list also contains information that only applies to a specific process, such as the minimum length at which the machine is cut. Finally, the setup list includes the information that is relevant for picking and assembling the tools.
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With tool management, the company has a solid partner to ensure that production orders run effectively. Information on existing knowledge is recorded in the master data and can thus be accessed by all those involved at any time. Other programs make use of the data provided by the tool management. Here there are two ways the different programs access the data of the tool administration:
- Using the tool management database.
- Using integrated interfaces.