Bridging the gap between shop floor and ERP

Despite significant investments in ERP systems, many manufacturing companies continue to struggle to effectively manage their operations.

The main reason? Lack of accurate real-time data from production.

ERP (Enterprise Resource Planning) systems like those from SAP, Microsoft, and Infor are powerful – they assist with resource planning, inventory management, and order processing. However, their effectiveness largely depends on the quality and timeliness of the incoming data. Delayed, incomplete, or erroneous information leads to the ERP system losing its relevance — a reality that many manufacturing companies know all too well.

A customer sums up the problem:

“Our ERP system is our backbone. The issue: We don't trust it.”

Does this sound familiar?

• Shift logs are filled out by hand and must be manually entered into the ERP.

• Order planning and actual lead times are misaligned.

• Pre- and post-calculations do not match, and product costs are unclear.

• If daily targets are not met, it is unclear whether downtimes or reduced production output were the cause.

All of these are clear signs of an information gap between production and the ERP system. As a result, production managers must laboriously obtain information themselves on the shop floor, planners operate in a vacuum – and decisions are based on gut feeling instead of reliable data.

ERP systems are not designed to collect data directly from the shop floor. This is exactly where MES (Manufacturing Execution Systems) and BDE (Data Collection Systems) come in: They promise to close the gap. However, in practice, this promise often remains unfulfilled – because the necessary machine connectivity is lacking or manual processes dominate.

Manual data collection as the main problem

Many modern MES and BDE systems lack comprehensive machine connectivity. They only support a limited number of interfaces – making widespread machine connectivity, especially in heterogeneous plant environments, nearly impossible.

The only difference between pen and paper and an MES or BDE is often just that no paper is used anymore and data does not have to be manually entered into the ERP – the data collection itself remains manual.

Manual data collection with pen and paper

Manual data collection with MES or BDE

Whether handwritten or through a terminal, the manual input of production quantities, downtimes, or reasons for scrap has serious disadvantages:

• delayed, incomplete, or erroneous data,

• high effort and distraction for the operating personnel,

• double data entries in different systems,

• restricted transparency over processes and causes,

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

An automated feedback directly from the machine is therefore not a "nice-to-have", but a prerequisite for reliable data, informed decisions, and effective digital production control.

What the integration of production processes with ERP enables

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

This means:

• Production quantities are automatically allocated to orders.

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

• The filling out of shift logs is eliminated, as are double entries.

• The ERP reflects the reality on the shop floor.

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

Through seamless integration, concrete advantages arise:

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

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

• transparency over levers for improving 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 then 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 checks, etc.) for automated data processing, and

4. Transmission of data to the ERP or existing MES or BDE systems.

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

This is how integration with ENLYZE occurs

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

There are two proven methods for this:

Direct connection to the ERP: We transfer 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, eliminating a large part of the manual bookings.

Connection via existing MES or BDE system

Collecting and processing machine data

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

• raw data is transformed and enriched with production information,

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

• 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 occurs via:

• database accesses for on-premise systems or

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

In this process, we read the current order occupancy per machine and ensure that all production data is automatically and order-related recorded – clean, reliable, and traceable.

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

Conclusion: Machine data are the key to digital transformation in production

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

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 manage your production, respond flexibly to changes, and continuously improve, ENLYZE offers you a practical and scalable way – to finally close the gap between the shop floor and ERP and simultaneously create the foundation for the digital transformation of your production.