SAP MES for the Plastic Injection Molding Industry
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Implementation Highlights:
- Close collaboration between client and RTS
- Real-time Overall Equipment Performance visibility via Andon system
- Visual production work order MES Scheduler
- Web-based HMI Screens, integrated with PLC and SAP S4-Hana
- Ad-hoc reporting with options to export as CSV or send via email
- Scalable solution – Easily configure additional Injection Molding Presses and equipment on the fly
Challenges & Opportunities
Real-time visibility and dynamic work order sequencing at the equipment level
Identify lost production time and scrap in real time
Optimize internal plant material logistics using Automated Guided Vehicles (AGVs)
Seamless visibility to production data from S4-Hana and PLCs
Web-based HMI Screens at workstations
Provide operators with relevant workflow instructions and specific part drawings
Objectives
Provide real-time insight and control over production operations at the Plant, Line, and Equipment levels
Increase equipment utilization via Overall Equipment Effectiveness (OEE)
Automatic production reporting back to SAP S4-Hana
Equip operators, planners, and managers with accurate, real-time information through interactive dashboards
Create a data repository for Injection Molding Machines’ configuration, Mold maintenance management, and machine history
Benefits
Real-time visibility and dynamic work order sequencing at the equipment level
Identify lost production time and scrap in real time
Optimize internal plant material logistics using Automated Guided Vehicles (AGVs)
Seamless visibility to production data from S4-Hana and PLCs
Web-based HMI Screens at workstations
Provide operators with relevant workflow instructions and specific part drawings
Why SAP?
Seamless integration with SAP ERP/S4-Hana
Interactive & uniform user-interface
Secured role-based functionality
Real-time, bidirectional communication with plant equipment and ERP/S4-Hana
Web-based dashboards, available on smart mobile devices
Interested in Learn More?
Overview
The SAP MII solution bridges the gap between the plant floor and the enterprise business system, enabling manufacturers to respond dynamically to unpredictable changes while ensuring efficient supply chain replenishment. RTS Consulting Automation delivered an industry-specific MES solution for the plastic injection molding sector, designed to improve production efficiency, equipment utilization, and provide valuable shop floor KPIs.
Key Solutions:
Mold Maintenance
Traceability
Real-time visibility to the plant floor
Improved visibility into production data
Enhanced product quality
Machine Availability & KPIs
The Andon dashboard provides real-time visibility into machine schedules, indicating the current cycle time for each work center. Supervisors can monitor the plant’s overall status from a single dashboard and drill down to specific equipment to take corrective action if necessary.
Visual Order Schedule Planner
Orders are downloaded from SAP S4-Hana and displayed in a searchable table. The visual schedule planner provides a graphical illustration of the schedule, enabling plant managers to plan, coordinate, and track orders easily. Orders can be rescheduled or reassigned by simply dragging and dropping them within the planner.
Reports
The solution provides ad-hoc reports highlighting problem areas such as downtime and scrap through Pareto charts and reason codes. Other reports include Color Change, Efficiency, Open Orders, Production, and Tooling Reports. Reports can be exported as CSV or sent via email.
Web-Enabled HMI Dashboards
SAP UI5-based HMI Screens are web-enabled and touch-ready, connecting to injection molding machines, PLCs, and SAP S4-Hana. These screens display real-time data from multiple entities and allow immediate confirmations back to S4-Hana.
Real-Time Order and Quality Status
The system monitors over two million combinations of product and production parameters, generating intelligent alerts and easy-to-manage reports. This ensures real-time visibility into orders and quality issues, enabling quick corrective action and minimizing production impact.
Mold Maintenance
The Mold Maintenance feature ensures proactive maintenance scheduling, improving tool longevity and product quality. Operators and planners are notified of potential mold issues during scheduling, preventing the use of unhealthy molds.
Summary
The SAP MII MES solution for the plastics industry provides real-time visibility, streamlines the planning process, enhances product quality, and improves production flexibility and agility. By enabling integration with SAP ERP/S4-Hana and shop floor PLCs, the solution provides end-to-end production management and quality control.