The solution involved integrating key ERP functionalities with the MES to enhance data acquisition from the shop floor and enable reliable tracking of production and Overall Equipment Effectiveness (OEE). They needed an approach that leveraged as much out-of-the-box (OOTB) MES functionalities as possible while ensuring full localization to Slovenian—the language of their facilities—which is not natively supported by most software. The project additionally required migration of existing functionalities, incorporating design improvements, and executing the transition within a customer-selected ecosystem. The entire process, from design to live production, had to be completed within a strict one-year timeline.
Improving data acquisition and OEE tracking with discrete MES in plastics manufacturing
Manufacturing Execution Systems (MES) are essential for standardization of production processes across multiple plants, providing a single source of truth while enabling real-time data collection for continuous improvement. Plastika Skaza needed to integrate MES with their ERP system to improve data acquisition and enhance Overall Equipment Effectiveness (OEE) tracking for better production efficiency and planning.
Their platform of choice was Opcenter Execution Discrete which they integrated with their ERP system. Implementing a solution designed for discrete manufacturing allowed the company to achieve seamless localization, accelerated processing times, and introduced reliable real-time KPI tracking. The integration of advanced automation and features like Automated Guided Vehicle (AGV) and automatic work order management with real-time data monitoring and tailored user interfaces enhanced production processes and operational efficiency.
Company profile
Industry:
Plastika Skaza is a Slovenian company with 45 years of experience in the field of plastics processing and injection moulding.
Product portfolio:
The company specializes in the production of plastic industrial components and housings, as well as innovative sustainable materials.
Location:
A Slovenian company, mostly exporting to Europe.
Impact
20+ hours monthly saved on work orders
- 10+ hours less downtime monthly
- 100% reduction in printed work instructions
- 13 hours saved monthly on instructions
“The integration of our MES with the ERP system provided a comprehensive view of our entire production line, fully automating processes and streamlining operations. The improvements are evident at every stage, with faster operation times, reduced human error, and a significant reduction in administrative tasks for our operators.”
Challenge
Solution
Complete tracking
of reground material
Our solution offers precise tracking of reground material usage throughout the entire production process, a capability previously unavailable. This enhancement reduces storage space requirements and extends the lifecycle of scrap pieces by regrinding and reusing them immediately in subsequent production stages.
Tailored HMI with
Mendix
By using the Mendix low-code platform a highly customized HMI was created that mirrors the previous system’s interface, ensuring a smooth user transition. This customization includes specific language, graphical style, and icons, all while enabling seamless updates in the Siemens ecosystem without production interruptions.
Automatic work order
changeover
The automatic work order changeover for identical materials completes the current work order, seamlessly starts the new one, and transfers specifications like nest number and regrind percentage, along with any excess quantities. This eliminates manual input, reduces supervisor workload, and speeds up production.
With migrating the existing system to the Siemens ecosystem, using Opcenter Execution Discrete as the core MES solution for discrete manufacturing, the focus was on maximizing the use of its out-of-the-box (OOTB) capabilities. Extending functionalities through the Opcenter Execution Foundation API and custom backend logic streamlined workflows such as start, complete, and end work orders, integrated automated user management, and enabled a single operator to manage multiple workstations simultaneously.
Direct ERP system integration
ERP integration brought operational and monitoring improvements, including label printing and cycle time monitoring. Previously, label printing was handled entirely manually; now, a new label messaging configuration was integrated into the ERP system, allowing seamless automation. Now, operators send the required number of labels through the ERP system to the central office, where they are printed and distributed accordingly.
Additionally, the ERP redesign brought an important update to one of the production counters. Before, cycle time was only displayed statically in the PLC, with no real-time monitoring. Since the implementation, cycle time is now imported from the ERP and linked to the produced material, enabling better detection of downtime, and improving overall efficiency.
Data collection and KPI calculations
On the automation side, the OPC server was employed to collect data from field devices and share it with clients via OPC UA. This was connected to Opcenter Connect MOM, which manages communication across all levels of the ISA-95 pyramid within the MES. The essential data was defined, including message types, channels, and credentials, ensuring that all platforms could communicate effectively in a unified language.
The collection and monitoring of Key Performance Indicators (KPIs) was ensured by integrating Opcenter Intelligence for Cloud, a solution based on Amazon Web Services (AWS). This allowed real-time monitoring of over 100 workstations on the factory floor and enabled the creation of custom dashboards and reports using Amazon QuickSight. The system also allowed near real-time customization of reporting criteria, such as adjusting allowable production scrap reasons, relocating workstations between production areas, and updating downtime justification elements or machine hierarchy.
For the interface design, Mendix, a low-code platform with extensive customization capabilities, was used allowing seamless integration with various software platforms. Custom displays were developed that aggregate data from multiple sources, presenting it in a single, unified view. The data presented to users is dynamically tailored based on their role, enabling very granular customization of application permissions. Sassy Cascading Style Sheets (SCSS) was utilized to create a clean and friendly user interface closely resembling the original HMIs, while maintaining a consistent look and feel across the application.
Digital work instructions
Digitizing work instructions ensure constant access to the latest manufacturing procedures, automatically updated with each work order. This reduces paper usage and provides role-specific information through an external link in the Mendix web application. By eliminating printed instructions, technologists save 30 minutes daily, allowing them to focus on more critical tasks.
AGV integration
The production line features Automated Guided Vehicles (AGVs), reducing pallet processing time from 5 minutes to just 1 minute. By activating AGV control through the MES HMI, operators can be reassigned to higher-value tasks, saving around 200 hours of manual labour per month. The direct AGV trolley call via MES also eliminated the need for extensive cabling and mechanical switches, thus saving funds as well as simplifying the system architecture. Furthermore, this function now triggers work order label printing for AGVs, streamlining two tasks into one.
Automatic user management
The system automates labour reporting to the ERP, ensuring accuracy and efficiency. User access is refreshed daily, allowing only current employees to log in. At the end of each shift, the system automatically removes remaining operators from the active list, preventing human error and ensuring precise labour reporting.
Results
The integration of AVG trolley calls through MES eliminated the need for extensive cabling and mechanical switch installations, delivering immediate cost savings and optimized data flow. MES streamlined work order initiation, while automated tracking of regrind and recycled material eliminated manual ERP corrections, ensuring accurate stock and consumption data. Downtime was significantly reduced, as real-time cycle time monitoring enabled faster issue detection, even on older injection molding machines. Additionally, digital work instructions replaced printed materials entirely, providing technologists with instant access to up-to-date instructions, saving valuable working hours each month and minimizing operational errors.
20+
hours monthly saved on work orders
Faster work order initiation achieved through automated records for regrind material.
10+
hours less downtime monthly
Accurate cycle time readings
enable faster downtime
detection.
13
hours saved monthly on instructions
Work instruction digitalization saves the technologist over 30 minutes daily.