Direct Integration of Manufacturing Systems with SAP

SAP PCo offers the online collection of process parameters, order and test data as well as real-time processing of events and signals over various machine interfaces. Beside device-specific message adapters and PLC interfaces control interfaces using OPC integration are available:

• UA: "Unified Architecture“ for platform-independent OPC servers with enhanced data security.
• DA: "Data Access" for OPC servers on the Microsoft platform with COM/DCOM.
• AE: "Alarm & Events" for OPC servers on the Microsoft platform with COM/DCOM.

"Rule-based agents" ensure that events are suitably filtered and linked, and no information is lost. Messages formed in this way are delivered to SAP MII or other SAP applications by Web-Services.

Available special equipment connections are continually being expanded. Please call get the latest status in terms of your manufacturing equipment.

The following benefits accrue from using SAP PCo for a direct connection between shop floor IT and Manufacturing Facilities:

• Reduction of integration risks usually associated with device communication through a simple application to the factory network.
• Faster deployment through pre-configured machine connections with frequently used interface protocols and standards.
• High degree of standardization based on Microsoft and SAP technologies.
• Investment security combined with a long-term development strategy.

We integrate your plant and machinery based on extensive experience with direct connection between manufacturing facilities and SAP solutions.

For this we deliver an integration approach that considers not just a single project, but is transferable to the maximum number of production facilities at your plants or your company. We speak the language of your plant maintenance staff and  machine suppliers and follow the safety policies of the IT department.

In addition to configuring specific PCo "agents," we take responsibility for the corresponding SAP-related interfaces. Additional software components from SALT Solutions, such as a “protocol factory”, special SPS connectors and simulators enable us to connect even complex systems directly to SAP.

SAP machine integration examples applying SAP MII and PCo:

AES – Chemunex DCount 2:
Measurement allocation to the SAP QM inspection lot by using the LIMS-export function and the file-monitoring adapter.

Arburg – Injection molding machines 270M/320C/570C:
Machine control, featuring downloads/uploads of machine settings, order start and request of machine states and number of shoots in connection with the Arburg Host Computer System (ALS). 

Brucker - MPA analysis system:
Application of the SAP PCo- file- monitoring adapter for the transfer of  analytical results from the device's internal log file and the allocation to the inspection lots in SAP QM.

Buhmann – Servocart C400:
Application of the OPC-DA-adapter for the determination of various machine states and error codes. An additional manual entry enables the classification of downtime causes according to VDMA 66412-1.

Engel – Injection molding machines  eMax 200 / Victory 330:
Order start, DNC-functions and machine data collection via file-, databank- and telegram interfaces by applying the ALS, featuring the Euromap E63-log. 

Fanuc – CNC-control series 0M
Direct access of switching signals for the determination of operation- and downtimes by means of the WAGO-I/O-system in addition to an OPC-DA-servers for the SAP ME  availability analysis.

FOSS - MilkoScan FT120:
Transfer of audit records from the internal data storage of the analysis system using a device-specific PCo SAP adapter for linking the data to the inspection lot in SAP QM.

Hurth –Gear slotting machines ZS 240T/ZSA220
Recording of switching signals via WAGO-bus modules and OPC for the determination of machine cycles and downtimes, enabling production analysis (SAP ME) and an order confirmation to ERP.

Intermec – Mobile data terminal C3:
Barcode scanner integration, featuring a direct display of SAP ME dialogs via Web-Services for the documentation of traceability-information.

de Man - Bag sealing machine:
Start and stop messages ,featuring machine-specific downtimes via the TCP/IP message adapter and an information standardization for the VDMA-compliant key figure determination.

Motorola – Mobiles data terminal MC9x90K:
Barcode scanner integration, featuring a direct display of SAP ME dialogs via Web-Services for the documentation of traceability-information.

OAS - Scale System:
Event-driven combination of weighing results from the scale data storage, featuring  order and job data in SAP ERP via the DB-Interface.

Properitär – UNIX-based installation process:
Transfer of disturbance- and downtime notifications for the display and analysis of the installation utilization ratio by applying the file-monitoring-adapter.

Siemens – Simatic RF600:
Registration of goods entries- and issues via the RFID-system (EPC1 Gen2) in combination with the  RFID management system Crosstalk.

Siemens – Simatic S7-300
Determination of operating- and downtime hours for an SAP ME- availability analysis of two customized installations by applying OPC-DA adapters.

Siemens – Simatic S7-400
SAP ERP integration of an interlinked cleaning station, featuring a scale system for the small parts production by a direct control via the TCP/IP-telegrams.

Siemens – WinCC:
Inspection data collection dialogs for SAP QM directly at the WinCC-stations by applying .NET Controls and Web-Services.

Weber - Slicer 902/903:
Identification of VDMA-compliant disturbance-classes of different machine states and error codes using SAP PCo (OPC-DA adapter).