Shop Floor Integration with SAP Digital Manufacturing Seamless integration for transparent and intelligent production processes
Intelligently Connecting Machines, Data, and SAP
A machine alone does not create transparency. Only the interaction between machines, sensors, shop floor applications, and SAP systems forms the foundation for efficient, digital production.
However, production environments vary considerably. Different machine manufacturers, communication protocols, levels of automation, and legacy system landscapes often hinder a seamless flow of information.
IGZ connects machines, production facilities, and digital applications with SAP Digital Manufacturing. This creates an integration architecture tailored to your processes, technical requirements, and long-term digitalization goals.
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Shop Floor Integration for Efficient Data Exchange
The principle of the digital factory is based on holistic networking and efficient data exchange. This results in ongoing optimization of planning and operational processes.
For SAP customers, a direct machine connection to the SAP Manufacturing Execution systems (SAP DM and SAP ME/MII) is available: This connection allows you to record the relevant production data of the individual machines in your systems. The machines are connected across all machines and technologies.
The SAP Plant Connectivity (SAP PCo) component also enables the active exchange of process parameters, production programs or setting parameters with the machines.
Integration of Heterogeneous Machines and Shop Floor Systems
Production processes are as diverse as the machines, control systems, and applications used in them. Depending on the industry and specific application, a wide variety of systems must communicate with one another reliably and efficiently.
Typical Components
- Production Facilities and Machinery
- PLCs
- Sensors and measurement systems
- Testing and quality control systems
- Weighing, dosing, packaging, and filling systems
- Custom shop floor applications
Typical Communication
- OPC UA
- MQTT and REST
- S7 and Modbus
- TCP/IP and Web Services
- Databases
- IO-Link and Other Standards
IGZ brings together experience from a variety of production environments. This makes it possible to integrate existing systems in stages, standardize communication channels, and flexibly accommodate new requirements.
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Making Production Data Useful in Smart Ways
Connecting machines is often just the first step. The real added value comes when machine statuses, process values, and quality information are organized and linked to the respective production context.
This transforms individual signals into actionable information for production, quality assurance, and management. At the same time, it creates a reliable foundation for continuous improvement and future analytics or AI scenarios.
- Operational and Process Data Collection
- OEE and Equipment Monitoring
- Quality evaluations and SPC
- Traceability
- Production reporting and analytics
The Right Integration Architecture for Your Shop Floor
Not every production environment has the same requirements in terms of integration, protocol diversity, data storage, and availability. That is why IGZ consistently tailors the architecture to your goals and requirements.
Various integration options are available for implementation, which can be used individually or combined as needed:
SAP Production Connector
Suitable for:
Standardized machine integration and direct connection to SAP Digital Manufacturing
Strengths:
SAP standard solution, lean architecture, and buffering of machine data
Industrial Data Platform
Suitable for:
Advanced integration scenarios, a wide variety of protocols, and local data processing and storage
Strengths:
Flexible connectivity, logging, contextualization, aggregation, and local buffers and queues
The Industrial Data Platform significantly expands integration capabilities. For example, it can support additional protocols, local data storage, historical data archiving, contextualization, and the targeted aggregation of high-frequency production data. When combined with the SAP Production Connector, it creates a flexible integration architecture that is closely integrated with SAP.
Our partnership with United Manufacturing Hub (UMH) demonstrates how such an approach can be implemented in practice. The open-source platform supports more than 150 IT and OT protocols and enables the standardized connection of heterogeneous machine and plant landscapes.
Production data is captured, structured, and linked to the production context right at the shop floor level. This makes relevant information available in SAP Digital Manufacturing for production control, OEE, traceability, analytics, and future AI applications.
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From the Machine to SAP Digital Manufacturing
- Connecting
Machines: Integrate machines, control systems, and sensors using appropriate connectors. - Model
data: Consolidate, clean, and aggregate raw signals, and enrich them with production context. - Harmonize
assets: Link physical production structures consistently with the digital models in SAP Digital Manufacturing. - Provide
data: Securely transmit relevant information and reliably resend it in the event of interruptions.
Continuous Operation for Critical Production Processes
Production processes must function reliably. At the same time, requirements for availability, data consistency, and local process execution vary from company to company.
Therefore, there is no one-size-fits-all solution for ensuring uninterrupted operation. Depending on the target state and initial situation, appropriate measures and technologies are combined to form a customized operational strategy.
- Local data buffering and store-and-forward mechanisms
- Decentralized data storage as well as local buffers and queues
- Local integration and communication services
- Provision of selected job and machine parameters
- Edge-based functions for local production processes
- Redundancy and high-availability concepts for particularly critical areas
The right strategy can effectively combine the SAP Production Connector, an Industrial Data Platform, and SAP DM for Edge Computing. Key factors include the customer’s goals, the existing infrastructure, the required scope of functionality, and economically viable operating costs.
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Three Success Factors for the Connected Shop Floor
01 Integration of Everything
Connecting machines, systems, sensors, and applications across manufacturers and technologies.
02 Production Data
Collect and organize production data and leverage it to promote transparency, quality, and efficiency.
03 Continuous Operation
Secure production-critical processes with the right combination of buffering, platform, and edge functions.
Why IGZ?
Integration between the shop floor and SAP requires more than just the technical connection of individual interfaces. It is crucial to understand how machine communication, production data, SAP processes, and the demands of day-to-day operations interact.
IGZ combines comprehensive expertise in shop floor communication with many years of experience in SAP Digital Manufacturing. This results in field-proven integration models for a variety of production environments, ranging from manual manufacturing areas to highly automated lines.
- Comprehensive expertise in shop floor communication and machine integration
- In-depth understanding of SAP Digital Manufacturing and production processes
- Vendor-neutral evaluation of technologies and communication channels
- Field-proven integration patterns and reusable procedures
Do you have any questions? Contact us!
Talk to us about your requirements and benefit from our many years of experience integrating machines, production facilities, and complex shop floor systems into sophisticated SAP MES environments.
Sales SAP MES / DM
