Bridging the gap between shop floor and ERP

Manual data collection as a central obstacle to digitization

Many modern MES and BDE systems do not possess comprehensive machine connectivity. They only support a limited number of interfaces – making a widespread connection of machines, especially in heterogeneous plant parks, nearly impossible.

The only difference between pen and paper and an MES or BDE often lies in the fact that no paper is used anymore and data does not have to be manually transferred to the ERP – the data collection itself, however, remains manual.

Manual data collection with pen and paper

Manual data collection with MES or BDE

Whether handwritten or via a terminal, the manual entry of production quantities, downtimes, or reasons for scrap brings significant disadvantages:

• delayed, incomplete, or incorrect data,

• high effort and distraction for operating personnel,

• duplicate data entries in different systems,

• limited transparency over processes and causes,

• and dwindling trust in ERP data – with consequences for the entire production control.

Automated feedback directly from the machine is therefore not a "nice-to-have", but a fundamental requirement for robust data, informed decisions, and effective digital production control.

What the integration of production processes with the ERP enables

A production data platform automates the data flow from the machine to the ERP – reliably, precisely, and in real time. The ERP thus accurately reflects the activities in production. Managers and planners receive a current, end-to-end insight into production – not just at the end of the day or with days of delay. The cycle between planning and execution is closed, and decisions can be made based on facts at the right moment.

This means:

• Production quantities are automatically assigned to orders.

• Downtimes are recorded accurately; only the reason needs to be selected.

• the completion of shift logs is eliminated, as are duplicate entries.

• The ERP reflects reality on the shop floor.

Automated data collection with a production data platform such as the ENLYZE Manufacturing Data Platform

The added value: From gut feeling to data-driven control

Through seamless integration, concrete advantages emerge:

• an accurate calculation of production costs based on actual resource consumption (material, energy, machine time)

• a smarter production planning based on current machine availability and a faster reaction to unplanned downtimes

• transparency over the levers for improvement of production as well as the ability to objectively measure and communicate progress.

Existing MES or BDE systems do not need to be replaced for this – they are rather enhanced by machine data. Manual bookings are automated through intelligent processing of machine data.

This is how a production data platform connects machines and ERP

A production data platform enables:

1. Direct connection to machine controls and sensors,

2. Establishment of a standardized data layer,

3. Linking machine data with production context (e.g., orders, products, quality inspections, etc.) for automated data processing, and

4. Transmitting the data to the ERP or existing MES or BDE systems.

Production data platforms thus provide the foundation for manufacturing companies to control their production in a data-driven manner and continuously improve.

Production data platforms are the cornerstone for reliable ERP data that can be trusted.

This is how ERP integration with ENLYZE works

Our integration experts ensure that both machine data and production context (e.g., order and product data) are smoothly captured, stored in the ENLYZE Manufacturing Data Platform, and integrated into the ERP or MES system.

There are two proven ways to do this:

Direct connection to the ERP: We transfer the data from production directly to the ERP system.

Direct connection to the ERP system

Connection to existing MES: We automatically supply your existing MES system with machine data, so a large part of the manual bookings is eliminated.

Connection via existing MES or BDE system

Collect and process machine data

The machine data collection takes place via our edge device SPARK, which communicates directly with the OT (Operational Technology) data sources (e.g., programmable logic controllers (PLC), sensors). Based on this:

• raw data is transformed and enriched with production information,

• automatically generated feedback on quantities, downtimes, and other key figures is created,

• all relevant information is structured and available for your ERP system.

ERP and MES Integration – simple and robust

The connection to the ERP or MES system is carried out via:

• database access for on-premise systems or

• open interfaces (APIs) for cloud or hybrid systems.

We read the current order occupancy per machine and ensure that all production data is automatically and order-related written back – clean, reliable, and traceable.

The data in the ERP system now reflects reality in production. The big hurdle: a comprehensive digitization of all machines, even in a heterogeneous plant park, has been overcome.

Conclusion: Machine data is the key to the digitization of production

Integrating machine data not only enables faster but, above all, more informed decisions – from the shift management to management.

Many goals of Industry 4.0 – such as predictive maintenance, autonomous production lines, or dynamically planned production - are not realizable without precise real-time data from machines and sensors.

If you want to centrally control your manufacturing, react flexibly to changes, and continuously improve, ENLYZE offers you a practical and scalable way – to finally close the gap between shop floor and ERP while also laying the foundation for the digital transformation of your production.