How does the interaction between MES and ERP optimize processes on the shop floor?

Every system, whether ERP (Enterprise Resource Planning) or MES (Manufacturing Execution System), has its own unique selling points. But while ERP systems are now standard in practice for everything to do with order management or work planning, many companies do not realize the potential offered by the interaction of ERP in combination with a smart MES solution.

The digital, smart networked factory supplements the functions of the ERP solution with real-time data from production and combines them profitably. In addition, the MES enables access to a lot of production-relevant information and important data from the ERP directly in production and back. This interaction across many areas of a company can significantly increase productivity in production and sustainably optimize processes.

By integrating both systems, processes on the shop floor can be optimized in many ways:

• Continuous flow of information
• Improved production planning and control
• Increased transparency and traceability
• Reduction of errors and manual entries
• Efficient resource management

MES and ERP in dialog

The ERP plans and controls company resources at a high level (e.g. material requirements, orders, capacities). The MES implements these plans in real time on the shop floor (e.g. machine control, order tracking, quality assurance). The bidirectional exchange between ERP and the MES system ensures that all data can be used anywhere without loss and reliably. Changes in the production plan (e.g. rush orders, machine breakdowns) are quickly recorded and passed on.

The MES Software EMC is compatible with all common ERP solutions and thus guarantees perfect interaction. Data flows in both directions. In other words, from the ERP to the machine control system and back again.

Send order data from the ERP down to the machine control system

With the networking of MES and ERP, it takes just one click to send the necessary data for the planned orders digitally to the machine control system. The employee at the machine can see all important order-related information in detail on the MES terminal, such as the current status of orders and work processes, interruptions and order progress, comparison of target and actual values or even the order backlog and order sequence. This means that overproduction is immediately recognizable.

In addition, real machine statuses, availabilities and set-up times are taken into account for detailed planning in the MES. And in more detail than the ERP. The MES reports these back to the ERP, which allows plan adjustments to be made based on the current status messages. This ensures improved production planning and control.

Direct connection of machines and workstations

Using OPC UA or smart IoT modules, all machines, whether new or old, can be easily connected directly. Operating data is recorded digitally during operation directly at the MES terminal. This means that manual or semi-automated workstations are also connected to the ERP.

The recorded live data from the shop floor (e.g. production status, quality, downtimes) flows into the ERP. This guarantees that the same “knowledge” and all information is available at all levels.

The positive effects of the integration between the two systems quickly become apparent. The processes on the shop floor are shortened and optimized. The connection supplements the ERP system with valid, automatically recorded data. This provides transparency for the entire company and increases the ability to react, for example in the event of production delays.

Smart monitoring of production

Depending on the OPC-UA interface and its capabilities, automated production monitoring can display information or instructions immediately. The employee receives digital work instructions directly from the ERP/MES, which minimizes operating errors and rework.

The ERP knows planned requirements, the MES knows the actual consumption and material status. For example, when the order quantity is reached, this is shown directly on the machine display via a window. This enables rapid intervention and prevents unnecessary overproduction.

The combination of ERP and MES therefore enables just-in-time material provision, reduces storage costs and improves capacity utilization.

Complete documentation

The networking of MES and ERP enables complete and seamless documentation of process data of varying quality. Values such as energy, air, temperature or speeds are important indicators for evaluating your own production and form the basis of a continuous improvement process. Valuable conclusions can be drawn from them, processes can be analyzed and potential for improvement can be easily identified and documented.

Conclusion

The integration of MES and ERP leads to greater transparency, flexibility, efficiency and quality in production. Companies that link these systems intelligently create a digitally integrated value chain – a core element of Industry 4.0.

As the same data forms the basis of the link, synergies are created that make working methods and processes easier in the long term, both on the shop floor and in control or management. The automated exchange makes many manual entries and processes superfluous. In addition, required data can be transferred from A to B and back again in real time – paperless and complete. All data is anchored in the system, guaranteeing that it can be found and retrieved quickly for future orders.

Contact us

Do you have further questions about the interaction of the MEs with the ERP and our MES Software EMC or about implementing your digital factory?
We will be happy to advise you and provide you with a personalized offer.

Simply call us on +49 7127 – 9231 10 or send us an e-mail to info@ite-ms.de