MES stands for Manufacturing Execution System and describes a software solution that closes the gap between the higher-level corporate management through SAP systems and the individual workstations on the shop floor level. It takes on central functions for monitoring and controlling production processes in real time.
In addition, an MES system bundles and processes production data and serves as a link between planning and operational implementation. MES systems are usually separate systems and therefore have several interfaces to other systems.
An MES system therefore, supports the implementation of efficient manufacturing processes and offers the possibility of optimizing production processes. MES systems are also seen as key technology for the digitalization of the shop floor. Common MES systems (see Figure 1) are independent systems and have an interface to the SAP system. Embedded MES solutions (see Figure 2), on the other hand, are integrated into SAP and do not require an external interface to control production.
Figure 1: Common MES landscape with a data interface for master data, production orders, feedback, etc.
Figure 2: Embedded MES solution in SAP without interfaces for better system performance
Below, the implementation steps between a standard and an embedded MES solution are compared and evaluated in terms of costs. We will have a look at seven points. The points themselves can be individually adapted and fulfil the basic functionalities of a manufacturing execution system:
- Size and complexity of the production environment
- Number of terminals to be integrated
- Scope of the desired MES functions – standard software vs. individual solution
- Required hardware: terminals, servers, etc.
- Setting up the interfaces
- Training of employees
- Consulting
- Beratung
MERGE as an Embedded-MES-Solution
Common MES systems are self-sufficient production control systems with interfaces to the SAP system and production machines. The functionality is guaranteed by the MES system, whereby the interfaces with the SAP system and the production machines must work. MERGE, on the other hand, has already been integrated in the SAP system and the functionality of the MES system is guaranteed by the SAP system, which is not impaired in its functionality by other SAP components.
The comparison of the implementation costs of a common MES and MERGE depends on various factors, but with MERGE some implementation steps are obsolete as the production control is mapped in the SAP system. This means that implementation costs for setting up interfaces or production terminals, for example, can be saved. The essential components for introducing an MES system are listed below. The components are briefly explained and evaluated in terms of implementation costs.
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Size and complexity of the production environment
This point refers to the size of the company and the number of locations, production lines and workstations. The more locations, production lines and workstations there are in an MES system, the more data must be maintained in the MES and SAP system. MERGE, on the other hand, accesses a central data structure and only requires one system with the data needed to control production.
Number of terminals to be integrated
The terminals on which the production steps are displayed and on which the production employee is able to use the production functions of the MES require a configuration of the respective software, which must be set up specifically for the workplace. MERGE, on the other hand, can be used flexibly and the production functions are called up using an Internet browser. The production employee only has to log in with his access data and select his workplace in order to be able to access the workplace-specific work list. Logging in can take place on a stationary terminal or on a mobile tablet solution. Setting up the stationary MERGE terminals and the mobile MERGE solution is simple and cost-effective, as they use proven browser technologies and are included in the scope of delivery as an “out-of-the-box solution”.
Scope of the desired MES functions – standard software vs. individual solution
Standalone MES systems offer a variety of standard functions, whereas MERGE focuses on basic functionalities such as feedback and data capture, and the standard functions can be adapted using customizing options. The basic MES functionality can be integrated with other SAP components (e.g. PP/DS, EWM) in order to exploit the full potential of MERGE. With standalone MES systems, the standard functions cannot usually be adapted and must be implemented individually. The basic MERGE functionalities, on the other hand, are continuously expanded and the customizing options are refined and updated.
Required hardware: terminals, servers, etc.
The common MES landscape is based on stationary terminals and requires its own server to function, on which the same master data as in the SAP system must be available in order to be able to communicate with each other. The MERGE system landscape, on the other hand, uses a uniform database and does not require any interfaces to ensure functionality. This has the advantage that the MES functionality takes place directly in SAP, and data collection is possible on the MERGE terminals. Additionally, MERGE offers a mobile “out-of-the-box solution”, which simplifies the connection of the MERGE terminals.
Setting up the interfaces
In standalone MES systems, the interfaces to the SAP system must be set up and maintained in both systems for the external input and output side in order to receive and send IDoc files correctly. There are no external interfaces in MERGE. Only internal interfaces can be set up, for example to ensure a collective transfer of IDoc files and thus the performance of the system. The data is collected for internal processing and transferred to the internal interface when it is to be processed.
Employee training
The difference of the standalone MES system and MERGE training depends on the complexity of the processes or the system support. MERGE combines a simple usability design and flexible adaptation to the process in use, so that the production employee is optimally supported in carrying out his work. Training SAP users in interaction with SAP PP is carried out by our qualified SAP consultants to offer SAP users a holistic view of the MERGE and PP functionality.
Consulting
The consulting service for common MES systems only relates to the MES system itself. This means that a high level of coordination effort is required between the MES and SAP consultants at the interface. With the consulting service for MERGE, you get a holistic view of the embedded MES system and benefit from our many years of SAP expertise. The coordination effort for the SAP PP module is minimized by the solution and the coordination with SAP PP is not foreign to the subject, as the same terminology is used.
The comparison of functionalities and implementation costs of common MES systems and MERGE depends on various factors, but with MERGE some implementation steps become obsolete because production control is mapped directly in the SAP system. The functionalities of MERGE are based on the basic requirements of manufacturing execution systems and can be individually expanded. This means that both implementation costs and running costs can be minimized compared to common MES systems.
Please feel free to contact us! Together we will examine your individual requirements and assess the benefits of implementing MERGE. It does not matter whether you already have an existing MES system in use or whether you are looking for an MES solution.
