This MES integration turns milk production into a transparent showcase

It is an MES for “Germany’s first organic dairy” and, moreover, one of the most sustainable dairies in Europe. By deciding to integrate a new MES (Manufacturing Execution System), Molkerei Berchtesgadener Land is taking a major step toward digital transformation: greater transparency, automated planning capabilities, and, of course, even more efficient and secure processes. The automation concept focuses on integrating CSB’s ERP system for production planning and analytics with the existing production facilities.

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Transparency in the production process

Data exchange as a booster for automated planning

The core function of our MES solution is to automatically send production orders created in CSB to the manufacturing equipment. In turn, the equipment transmits the data it has recorded—such as quantity, number of units, machine status, and order status—back to CSB.

The particular challenge here lies in the sheer volume of data and the wide variety of individual configurations. Each production system has its own communication interface and provides different data, depending on the system type. The goal is to “standardize” these interfaces between CSB and the production systems so that data exchange can take place at all.

An MES database as the key to greater transparency

Production data from the ERP system is received in an SQL database , converted, and made available for the respective production line. All feedback from the production lines is collected and processed so that it can be transmitted to the ERP system via a defined interface. Materials management can also be automatically evaluated and improved based on target and actual data.

Our client not only benefits from improved production and process planning, but also gains valuable insights and tools to optimize production capacity even further.

Automated order planning

Our MES system provides us with an optimal interface between the ERP and the shop floor, where all relevant data can be captured and transferred.

Live data from production

Machine data and status information can be reported to the ERP system. This enables more accurate planning.

Transparency throughout the entire process

Real-time tracking of reported batches—from planning through to the actual production line and palletizing.

Time savings

Operators are significantly relieved of workload thanks to global settings for production parameters. All production, inventory, quality, and maintenance processes are managed digitally.

100 percent automated data communication

The customer can transfer production schedules from CSB directly to the production lines and, if necessary, set all production parameters globally rather than individually for each machine.

”We respond flexibly to our customers and tailor our MES to their needs. This is the only way to fully leverage the strengths of an order planning system!
Simon SchmittProjektingenieur

automation excellence

Separate programming for each interface

The interfaces for each production unit must be defined and designed individually in advance. As a result, each interface is essentially one-of-a-kind and is fine-tuned in a very short time thanks to our team’s extensive experience and automation expertise. Depending on the production system, communication takes place either cyclically or on an event-driven basis.

Live broadcast

Flexible production control and fully automated transfer of production plans from the ERP system thanks to a customized interface design.

Flexible connectivity

ERP integration with any conceivable production system—even those without standardized interfaces—thanks to manesoft’s proven PLANT MATCH middleware.

Automated materials management

Continuous comparison of target and actual data to ensure safe and efficient dairy production.

Custom design

Customization of the MES to align with individual improvement drivers and specific process requirements.

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An MES for germany’s most sustainable dairy