SAP Manufacturing Industry 4.0 with the SAP software suite

On the road towards INDUSTRY 4.0, the continued improvement and more widespread use of MES functionality – and in all sectors of manufacturing – is of central importance. The familiar MES topics of transparency and traceability – plus efficient personnel management – are now being extended to include system integration and sensor data analysis while also ensuring flexibility and adaptability in production. Open systems, with service-oriented, decentralised architecture and standardised options for interfacing machinery are important preconditions here. Complementing their extensive core functions, MES systems from SAP also have these properties from the outset.

With SAP Manufacturing Execution (SAP ME), SAP has provided a fully-featured and configurable MES system for use in discrete manufacturing.
SAP MII (SAP Manufacturing Integration and Intelligence) is the proven solution for the process industry. Pre-configured solutions from IGZ for bulk production, continuous flow production and filling/packaging build on this by ensuring rapid rollouts and a solid ROI.

Integration with SAP ERP (SAP Enterprise-Resource-Planning) is part of the solution! The MES modules from SAP are the only MES systems on the market that actually offer integration as standard plus a range of other integration scenarios with SAP ERP (SAP Enterprise-Resource-Planning) out-of-the-box. This ensures that ERP integration work will be compatible with later releases.

The IGZ service portfolio not only includes strategic consulting on MES deployment and subsequent SAP implementation as well as direct SAP/system/machinery integration but also covers any and all manual or automated production facilities and shopfloor systems.

IGZ – the SAP Engineers – can look back on a wealth of experience and reference projects both within discrete manufacturing and the process industry.

Our customers' primary objective is a high degree of SAP integration and the increase in efficiency, stability, transparency and quality, as well as reductions in ongoing operating costs.


Fields of competences

Machine interfacing

With the in SAP Manufacturing Suite integrated component SAP Plant Connectivity (SAP PCO), SAP offers the following options direct machine interfacing, automatic detection of machine conditions and quantities, acquisition and storage of various process data.


Effective Plant Data

With SAP ME and SAP MII, all work steps in production can be tracked and monitored on the shop floor without gaps and up-to-date. This means that precise details about the progress and status of production orders are available at all times.


Production Control Center

Graphical planning boards for the detailed scheduling and control of your orders and resources give you quick access to an overview of the status and progress of your current production orders and future scheduling at any time.



On the logistics side, SAP provides a platform for production logistics with Extended Warehouse Management (SAP EWM). This close integration between logistics and production can be optimally realised via SAP ME and SAP EWM.


SAP Modules

SAP DMC (SAP Digital Manufacturing Cloud)

With SAP DMC (Digital Manufacturing Cloud), SAP has launched a flexibly scalable cloud MES system that supports production managers and employees on the store floor and guides them through each individual assembly step, even with batch size 1.

The manufacturing solution is directly integrated with SAP S/4HANA as well as the existing SAP ERP ECC, which is used to plan production orders including available resources (machines, employees, etc.) and trigger all follow-up processes. The cloud-based MES system also creates end-to-end transparency across sites, even on a global level, about plants, selected workstations or individual machines.

Analysis functions in conjunction with KPIs (Key Performance Indicators) and Machine Learning (ML) promote rapid decision-making. The generated reports can be displayed in the cloud - also in real time.




SAP ME (SAP Manufacturing Execution)

SAP ME is the MES system from SAP for all your discrete manufacturing needs!
SAP Manufacturing Execution is a high-performance, scalable, enterprise-level manufacturing solution that enables complete, component-level and material-level visibility for both individual and global installations. 

SAP ME supports and enables:  

  • Error-free development and production from day one
  • Detailed modelling of the manufacturing process 
  • Dynamic control and monitoring at WIP level 

In addition, production information is collected and communicated in real time throughout the entire production life cycle. 
The result is an aggregated record of the entire product history. This is stored permanently, thereby fulfilling the statutory documentation requirements and contributing to efficient decision-making.



SAP MII (SAP Manufacturing Integration and Intelligence)

With SAP MII, SAP provides a web-based, standardised and flexible IT platform for vertical integration in production. This combines the various steps necessary for process-oriented production with SAP ERP. 

As a central information hub, SAP MII extracts and interprets data from various sources (such as shop floor systems), and offers a wide range of monitoring, controlling and control options for process optimisation and increased production efficiency. 

This makes SAP MII the central element of a KPI-driven production process that is characterised by efficiency, availability and quality. SAP MII relies on tight integration with SAP ERP. SAP MII makes it possible to act early, rather than to react, and also to exploit and purposefully control hitherto hidden productivity and quality potential. 

Via our proprietary SAP MII Best Practices, IGZ offers pre-configured solutions for integrated and efficient production processes throughout SAP MII, especially for process industries.



IGZ Best Practices

Assembly-by-Motion® – Intelligent assembly control with gesture control

Production managers are primarily interested in increasing efficiency, maximizing assembly safety, and quickly training new employees. With ASSEMBLY-BY-MOTION®, IGZ offers the possibility to ensure process safety with maximum efficiency by means of easy-to-use camera-supported technology.

The gesture-supported work with ASSEMBLY-BY-MOTION®, as well as the intelligent online validation of the assembly by means of a camera system, allows the employees to fully concentrate on the assembly process.


Fill + Pack® – Automated filling and packaging lines with SAP MES

For the consumer products sector, IGZ provides SAP MII (SAP Manufacturing Integration and Intelligence) Best Practice Fill + Pack, a solution for efficient filling and packaging processes for liquid products or bulk goods.

Based on SAP MII, IGZ provides modular best practice solutions that enable the creation of transparent processes in automated filling and packaging within the shortest possible realization time throughout the plant and company.


Flow + Pack® – Automated assembly lines with SAP MES

With the SAP MII Best Practice FLOW+PACK® IGZ provides a solution for efficient manufacturing and packaging processes in automated interlinked production lines.

Based on SAP MII, IGZ provides modular best practice solutions that enable the creation of transparent processes in automated manufacturing and packaging across plants and companies within the shortest possible implementation time.


Electronic Work Instruction – Increased process reliability through online plant management

With the Best Practice Electronic Work Instruction, IGZ offers a system-guided processing of SAP ERP control recipes. Employees are thus guided safely through the manufacturing process of a process order.

The system guidance is based on the processing of a control recipe by means of process instructions and phases. The control recipe is managed centrally in SAP ERP. In addition to the precise guidance of the employee through the control recipe, EWI additionally secures the manufacturing process through the parameter supply of technical systems by means of a direct connection to SAP MII.


Extended OEE 4.0 – Increasing effectiveness through key production figures

Total equipment effectiveness is a well-known indicator within the TPM (Total Productive Maintenance) concept. As a key figure, it is used to determine, monitor and optimize availability, performance level and quality in relation to the production process.

With the help of measurable KPIs, the SAP ME- / MII-based OEE is used to keep a comprehensive eye on production performance at all times and to identify where and why performance losses occur. An order-related profitability calculation can be performed and target-oriented countermeasures can be implemented quickly and effectively.


Order Cockpit 4.0 – Order fine control

Scheduled production or process orders are made available from SAP ERP (SAP Enterprise Resource Planning) (PP) for production control after release in SAP ME/MII (SAP Manufacturing Execution/Manufacturing Integration and Intelligence).

With the SAP ME/MII-based (SAP Manufacturing Execution/Manufacturing Integration and Intelligence) detailed planning (interactive graphical order control station), orders can be distributed and started on available machines, taking into account current shop-floor information such as the current machine status, taking into account necessary and available resources.


Energy Optimization – Energy management and optimization

With SAP MII Energy Optimization®, IGZ provides a solution that reduces costs by deriving energy-saving potential. The solution makes it possible to comprehensively visualize energy consumption online and to control it in an energy-optimized manner.

The need for efficient energy use arises with great urgency due to dwindling resources, rising and fluctuating energy costs, temporary supply failures and increasing pressure from the legislature.


Weighing & Dispensing® – Weighing and dosing in the process industry

SAP MII Best Practice WEIGHING + DISPENSING® from IGZ enables system-supported component weighing with direct connection of scales and dosing systems. The employee is guided through the complete weighing and dosing process with consideration of the optimal batch division and blending (batch blending).

Various sequence and weighing variants optimize the workflows and support ergonomic processing for the employee, thus facilitating process assurance and batch tracking.


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