SAP Digital Manufacturing for the digital factory in the process industry Industry solutions from IGZ for greater efficiency, transparency and sustainability
Manufacturers in the process industry are faced with the major task of aligning their production even more closely with efficiency, sustainability and transparency in order to meet growing regulations and market requirements. SAP Digital Manufacturing (SAP DM), the centerpiece of SAP's design-to-operate solution portfolio, provides an end-to-end, intelligent production environment.
With real-time visibility and seamless integration with SAP S/4HANA and SAP Extended Warehouse Management (EWM), SAP DM enables centralized data usage, process reliability and efficiency along the entire value chain. IGZ complements this with ready-made industry solutions such as FILL+PACK for filling and packaging processes (e.g. in the beverage and chemical industries) and FLOW+PACK for continuous processes (e.g. in the confectionery industry) in order to introduce new digital standards more quickly.
SAP DM ensures efficiency, transparency, traceability and sustainability
SAP Digital Manufacturing offers companies in the process industry numerous advantages that go beyond efficiency gains and create sustainable competitive advantages:
1. Real-time transparency and process reliability
SAP Digital Manufacturing provides production and plant managers with real-time visibility of KPIs on current production progress and machine statuses via configurable dashboards, enabling informed decisions and fast, data-based responses. Shift supervisors benefit from the REO (Resource Orchestration) module, which allows flexible scheduling and rescheduling of orders and thus ensures optimum utilization of highly automated systems. Production staff on the line benefit from user-friendly worker terminals that digitally display recipes and work instructions and ensure absolute process reliability through plausibility checks combined with preconfigured interlocking mechanisms.
2. Traceability
Particularly in sensitive sectors such as the food and chemical industries, the traceability of products and raw materials used is an essential criterion that must be met. SAP DM offers the necessary functions to ensure consistent and complete SAP end-to-end traceability of production batches and raw materials used.
3. Sustainability and resource conservation
SAP DM optimizes energy and material consumption, reduces waste and scrap through integrated quality assurance and OEE analyses. This lowers costs and enables the implementation of sustainable production targets, allowing companies to reduce their environmental footprint.
IGZ Best Practices: Solutions that raise production and quality to a new level
IGZ offers several preconfigured industry solutions based on SAP DM for various processes and requirements of the process industry. This shortens the realization time of the SAP DM implementation and ensures reliable project implementation.
FILL+PACK - the solution for automatic filling and packaging processes
This solution focuses on the food, beverage and consumer goods industry and is tailored to the special requirements of automatic filling and packaging processes.
FILL+PACK enables complete traceability and supports the recording of key performance indicators such as OEE (Overall Equipment Effectiveness), offers the option of fine order control and extended control station functionalities. This allows the entire production process to be monitored and optimized in real time.
FLOW+PACK - the solution for continuous flow processes
FLOW+PACK is ideal for the automation of interlinked production lines, such as those found in confectionery production. With functions such as a pre-configured control station and real-time quality checks, this best practice ensures that production progress and product quality remain transparent and controllable at all times. Necessary paper-based processes for quality data feedback are eliminated and paperless production becomes a reality.
Electronic Work Instruction (EWI) - the solution for bulk/manufacturing processes
EWI offers dynamic online worker guidance using detailed process specifications and phases based on the process order, which guides production employees through complex manufacturing processes in a structured and reliable manner. Integrated quality checks ensure the highest product quality. Automated process data acquisition and evaluation ensures 100% traceability.
The digital provision of constantly updated production-related documents and safety instructions ensures safe processes. The perfect solution for companies with complex processes and high quality requirements.
Weighing & dispensing - the solution for mixing and dosing processes
For precise weighing and dispensing processes, IGZ has developed Best Practice Weighing & Dispensing, a solution that ensures exact compliance with recipe specifications and tolerances. The direct connection of scales and dosing systems ensures process reliability and transparency. This supports more sustainable production by conserving resources through optimal use of materials.
Practical examples: With SAP and IGZ to the digital factory
IGZ has already successfully supported numerous companies in the introduction of SAP Digital Manufacturing solutions, applying proven, industry-specific best practices. The following examples illustrate how these projects have helped companies to optimize their production processes.
KRAIBURG TPE: A technological leap to harmonize production
The global manufacturer of thermoplastic elastomers is considered a "digital pioneer" in its industry thanks to the worldwide introduction of the innovative MES solution SAP DM. Thanks to a company-wide template and flexible scalability, the SAP architecture is ideally suited for the group-wide rollout and thus secures the future growth of KRAIBURG TPE on the basis of cross-location, standardized processes in the long term. The existing IT system landscape is harmonized and the distribution of tasks between ERP, MES and DCS is clearly regulated.
There is a continuous flow of information between the systems to ensure consistent data and a "single point of truth" at all times. Mr. Meier sums up the decision for the project as follows:
"SAP DM is a very good fit for a modern company like KRAIBURG TPE, which wants to position itself sustainably for the future in the course of digitalization. We are convinced that our new solution will also enable us to master future challenges in the production environment."
Griesson - de Beukelaer: Digital networking for top quality with FLOW+PACK
Quality tastes better: With Prinzen Rolle, Griesson Soft Cake and LEICHT&CROSS crispbread, Griesson - de Beukelaer, one of the leading companies in the European market for sweet and savory cookies, produces popular cookies and snacks using fully integrated IT systems.
In a constructive and results-oriented exchange, IGZ Best Practice FLOW+PACK was further developed from in-process quality inspections to event-driven inspections: End-to-end batch traceability, integrated control station functions and in-process controls support quality assurance in a food company. This has led to a significant increase in efficiency through the targeted reduction of inspection work and creates paperless production with a high degree of flexibility and transparency.
BASF: Efficient production control and OEE reporting with FILL+PACK
The chemical company BASF uses IGZ Best Practice FILL+PACK to optimize its production processes in the Agricultural Solutions segment. Eric Fritsche, Process Management BASF Agricultural Solutions, emphasizes the advantages:
"Thanks to the vertical integration of FILL+PACK, we have optimized our entire production control. The digitized documentation saves us manual work steps, which means that fewer corrections are necessary. In addition, the real-time feedback from the filling process helps us to plan appropriately. The information collected forms the basis for OEE reporting and system maintenance, allowing us to identify potential weak points at an early stage and optimize filling performance accordingly."
Shaping change: Into an innovative future with SAP DM
SAP Digital Manufacturing enables companies in the process industry to digitally map and centrally control their production processes. SAP's MES solution based on state-of-the-art cloud technology records all relevant production data, connects machines and systems and thus creates transparency and a wide range of control options in real time. This promotes the sustainability of production processes and forms the basis for new AI technologies.
IGZ industry solutions based on best practices also ensure that projects are implemented quickly and securely.
We look forward to hearing from you!
Back to overview
