MES in SAP

MES in SAP ERP means no middleware and no interfaces with maximum data transparency

X-NetMES is an MES system with a modular structure that utilizes the existing SAP ERP or S/4HANA data structure and enhances it with the requirements of an MES solution.

The X-NetMES portfolio covers all areas of a classic MES application:

  • Order data collection such as labour time, machine time or number of units in relation to the SAP order and work centre.

  • Labour time tracking for the registration of non-productive time to the collection of at work time (clock-in – clock-out).

  • Machine data logging with direct communication with the machine and process equipment.

  • Quality data collection in production for operator self-inspections or inspections during goods receipts.

  • Material data collection including registration of materials and quantities for consumption with batch or serial number (traceability).

  • Maintenance data collection to increase the availability of technical equipment and precise performance settlement.

  • Detailed planning for the precise management of the production flow and resources.

  • Cockpit for the current overview, evaluation of the past and as a measuring tool for the KVP.

X-NetMES also means: Standard software that is customized to meet the requirements of the respective production or assembly process through parametrization.

“Standard software is simply standard software with update capability!”

Industrie 4.0

The all-inclusive linking of all data of the digital factory (Cyber Physical Production) with the objective to optimize the processes and thereby increase productivity.

SAP is one of the data platforms of the digital factory.

We have ideas and tools for generating measurable productivity from this data.

X-NetMES has a modular structure and a specific workflow is mapped depending on the application. The processes are set up with a comprehensive customizing function.

The user interface is dynamically designed and can be adjusted for the specified workflow. Options for the classic interface based on BSP or a current S/4HANA Fiori variant are provided. All dialogues are displayed with a web browser. Accordingly, there are no restrictions with regard to the hardware. Of course, the dialogues can also be used on tablets or smartphones.

The X-NetMES Standard Suite requires few consulting and programming services

The result is a quick implementation that is gentle on resources.

X-NetMES is completely integrated in SAP ERP or S/4HANA. There is no use of middleware. We don’t use additional sub-components, such as SAP MII or SAP PCo.

The classic MES includes the registration of actual data for the order / operation. A dialogue for easy input accompanies the operator while working.

All common types of orders and activities are supported:

Production orders (PP)
Process orders (PP-PI)
Project orders (PS)
Maintenance orders (PM)
Cost centres / internal orders (CO)
Data is automatically collected by starting or stopping the activity type. Input for good / scrap quantities is verified.

An option to select a paperless or document-supported workflow is provided. In addition, operator management based on stored documentation is available.

A high degree of automation for input is possible in combination with other functions.

Labour time recording is structured in the following modules:

Labour time work centre
In contrast to the classic BDE with the registration of the account allocation of the operator time to the order and work centre, there is a qualified collection of activities (non-productive times) that cannot be allocated directly to an account.

Labour time at work
All times for the operator within his working time are collected with qualification. X-NetMES registers each “time slice” for the operator and distinguishes between time that can be allocated to an account and time that cannot be allocated to an account.

At work time terminal
The at work time is collected and posted in correlation with the SAP HR module (Human Resources). The operator can input his attendance and absence status on a separate at work time terminal.

This X-NetMES module replaces the middleware for at work time collection (clock-in / clock-out time). All common identification systems are supported (Legic, Mifare, etc.)

The structure of the machine time is roughly divided into processing, set-up / cleaning, downtime planned and downtime not planned.

X-NetMES collects these status values and posts the corresponding times to the SAP activity types. The qualification of breakdown data is a major component of the function.

Production quantities and related process parameters are also collected and posted.

The status and quantities can either be collected manually by the operator or automatically directly by the machine.

The machine is connected quite easily via:

A signal converter that collects the machine signals directly
An OPC connection that communicates with the machine control unit
An HTTP connection that is used to establish an individual communication path.
X-NetMES has standardized processes for each connection type. Approximately 5,000 machines have already been connected to SAP via X-NetMES worldwide. Whether it is Simatic, Sinumeric, Heidenhain, Allen Bradley, GE-Fanuc, etc. – our team has a solution.

With regard to traceability, it is important to know which inbound material was used in which outbound material. The inbound lot is a component of the outbound lot.

Backflush postings are prone to errors and a lot specification can slow the material flow.

X-NetMES provides a workflow for the proper consumption posting of the material that is used. The operator simply registers the applied batch (component) and its quantity. The data is posted directly with reference to the order or operation.

Another function is the collection of serial numbers for the order (production equipment) or for assembly. The operator uses a simple workflow to collect the individual parts and assigns them to an object.

There are no lengthy and error-prone recordings or retroactive manual transmissions of data to the SAP system.

The collection of maintenance services for the devices and systems represents the primary functional content of the X-NetMES maintenance data collection. The function is based on the SAP PM module (Plant Maintenance).

There is a differentiation between ad hoc maintenance and standard maintenance:

For ad hoc maintenance, the operator or the machine will initiate the maintenance operation (repair). The maintenance operator(s) enter(s) the services and materials directly at the X-NetMES terminal.

For standard maintenance, the maintenance operator is managed on the X-NetMES terminal. The activity and components are entered directly.

The focus of the X-NetMES quality data collection is the inspection during production.

Analogue to the QM inspection lot, the operator enters the quantitative and qualitative inspection characteristics at the X-NetMES terminal. A dynamic workflow that is derived from the SAP inspection plan guarantees an ergonomic operation.

There is an option to connect digital measuring devices. In addition, there are interfaces to complex inspection systems.

X-NetMES Studio is available for evaluation of the MES data. The display includes the current status of the work centre and the parametrizable display of evaluations.

The activity status for personnel and system is displayed colour-coded for each work centre. Information about the assignment and machine activity can be viewed at a glance.

Detailed evaluations are available on several levels. In the default setting, the levels are divided into area, cost centre, work centre and capacity.

Preset evaluations for the continuous improvement process, such as:

Process of the status on the level (cost centre / work centre), OEE, NEE, MTBF, failure data analyses, output in relation to various objects, shift reports, attendance statistics, etc. are available. The preset evaluations can be adjusted to suit individual needs. The trained administrator can store his own evaluations.

An SAP BI or SAP BW interface exists.