DIGITALIZATION
Providing engineering service for MES system
A manufacturing execution system (MES) is a software-based solution used in manufacturing to monitor and control production processes on the shop floor.
An MES is a software-based solution used in manufacturing to monitor and control production processes on the shop floor. In manufacturing operations management, an MES serves as a bridge between the planning and control systems of an enterprise, such as an enterprise resource planning (ERP) system, and the actual manufacturing operations.
The primary purpose of an MES is to track and document the transformation of raw materials into finished products in real time. It captures data from various sources, including machines, sensors and operators, to provide accurate and up-to-date information about the status of production activities.
An MES provides real-time visibility and control over production processes, enabling stakeholders to monitor operations, identify bottlenecks, minimize downtime and make informed decisions promptly. By facilitating optimized production planning and scheduling, MES systems ensure efficient resource allocation, workload balancing and on-time deliveries, leading to higher profitability.
They also play a critical role in quality assurance and compliance by enforcing quality control procedures, monitoring metrics and capturing real-time data. With their ability to manage inventory levels, track material movements and help ensure timely availability of materials, MES systems optimize inventory management and minimize production delays.
Moreover, MES systems enable data-driven decision-making by providing comprehensive and accurate production data, empowering organizations to continuously improve processes and optimize resource usage. MES systems can help decision-makers ascertain overall equipment effectiveness (OEE), a broad metric used to monitor manufacturing effectiveness.
By streamlining workflows, automating tasks and providing real-time feedback, MES systems enhance plant floor efficiency and productivity. Also, these management systems enable traceability and genealogy, crucial for industries with strict regulations, by tracking the movement of materials and processes throughout the smart manufacturing lifecycle.
Project – Data Acquisition for OPC / MES Interface
Providing engineering service to program the data exchange
Data acquisition for OPC Connectivity / MES interface solution provides true process visibility by data collection and time series data optimization. Islands of automation across plant tied together without compromising data resolution. OPC connectivity & MES enablement solution provides a window into all manufacturing operations.
Facility Monitoring and Control System - FMCS
Definition and Scope
The FMCS supports the plant infrastructure and utilities:
- HVAC Heating, Ventilation and Air Conditioning
- Water Treatment: RO, Ultra Pure Water (UPW)
- Waste Water Treatment (WWT)
- Gases and Chemicals
- Boiler & Heating
- Cooling System
- Low Voltage & Medium Voltage distribution
- Fire safety
- Security
The Integrated Architecture: Powering Your Plant
The FMCS for manufacturing is built upon a modular yet seamlessly integrated architecture, ensuring comprehensive control and optimization of every aspect of your plant's operations.
Sensors & Field Devices
The eyes and ears of the system, capturing critical data like temperature, humidity, pressure, energy consumption, and precise machine status — including flow meters for utilities and vibration sensors for equipment health.
PLCs / Industrial PCs
SIMATIC S7 series PLCs act as the intelligent brains, executing local automation tasks, collecting data from field devices, and ensuring precise control at the operational level.
HMIs / SCADA Systems
SIMATIC WinCC and WinCC Unified provide intuitive visualization, allowing operators to monitor real-time data, manage alarms, and control processes from user-friendly interfaces.
Networking & Communication
Secure industrial Ethernet protocols such as PROFINET and Industrial Wireless LAN ensure robust and reliable data exchange across the entire facility.
Data Management & Analytics
Platforms such as Siemens Xcelerator and MindSphere enable comprehensive data collection, secure storage, advanced analytics, and actionable insights for predictive maintenance and optimization.
Energy Management Systems
Specialized modules such as SIMATIC Energy Management monitor, analyze, and optimize energy consumption across utilities, identifying opportunities for significant savings.
The Foundation for Your Digital Transformation Journey
FMCS is not merely a control system; it is a critical enabler for your organization's digital transformation, seamlessly integrating into the broader framework of Industry 4.0 and the smart factory concept.
IT/OT Convergence
FMCS bridges the historical divide between plant-floor operational technology (OT) and enterprise information technology (IT) systems, creating a unified data environment for holistic insights.
Digital Twin Foundation
It enables a dynamic digital twin of your facility and production processes for real-time simulation, predictive analysis, and continuous optimization without impacting live operations.
Predictive Analytics & AI
By leveraging operational data collected by FMCS, advanced analytics and AI algorithms can predict equipment failures, optimize performance, and pave the way for autonomous operational segments.
Cloud Integration
Facility data can be connected to secure cloud platforms such as Siemens MindSphere for broader analysis, cross-plant comparisons, and collaborative decision-making.
Enhanced Resilience
Proactive identification of cyber and operational threats, coupled with improved responsiveness, significantly enhances the resilience and security of manufacturing operations.
Real-time Control and Optimization at Your Fingertips
FMCS offers comprehensive functionalities designed to provide unprecedented control over your manufacturing environment, ensuring optimal conditions and operational efficiency.
Environmental Control
Precision control of HVAC for sensitive manufacturing areas like clean rooms and laboratories, ensuring temperature and humidity stability critical for product integrity.
Utility Monitoring & Management
Comprehensive monitoring and optimization of electricity, gas, steam, and water (including UPW and wastewater) to reduce consumption and manage peak demand effectively.
Machine & Process Integration
Real-time monitoring of critical machine parameters (vibration, temperature, run time), integration with CNC machines and robots, and predictive maintenance capabilities.
Safety & Security Systems
Seamless integration with fire detection, access control, and emergency shutdown systems for a safer and more secure operational environment.
Reporting & Analytics
Customizable dashboards and historical data analysis for KPI tracking, including Overall Equipment Effectiveness (OEE), to inform strategic decisions.
Alarm & Event Management
Configurable alarms with instant notifications via SMS or email, coupled with detailed event logging for rapid response and troubleshooting.
Remote Monitoring & Control
Secure remote access enables operators and maintenance teams to monitor and control facility systems from anywhere, enhancing flexibility and response times.
Partnering for Success: Your Path to a Smarter Facility
Embarking on a journey to a smarter facility requires careful planning and expert partnership. OPSYS provides comprehensive support at every stage, from initial assessment to ongoing operations.
Key Implementation Considerations
Assessment
Thorough analysis of your current infrastructure, operational processes, and specific needs to define the scope.
Design & Engineering
Customizing the FMCS solution to align with your unique manufacturing requirements and objectives.
Integration
Seamlessly connecting the new FMCS with your existing systems, machinery, and IT infrastructure.
Cybersecurity Strategy
Developing a robust security framework to protect your operational data and control systems from threats.
Training & Support
Empowering your team with the knowledge and skills needed to operate, maintain, and maximize the new system.
How Siemens–Opsys Supports Your Journey
Consulting Services
Expert guidance from concept to completion, ensuring optimal solution design and strategy.
Project Management & Implementation
Dedicated teams to manage the entire project lifecycle, ensuring smooth deployment.
Training & Technical Support
Comprehensive programs and responsive support to ensure your team's proficiency and system reliability.
After-Sales Service & Maintenance
Ongoing support, updates, and maintenance to keep your FMCS performing at its peak.
Remote Monitoring & Managed Services
Proactive remote oversight and support for optimized industrial operations.
Driving Operational Excellence and Competitive Advantage
Implementing Siemens FMCS yields tangible, quantifiable benefits that translate directly into enhanced operational efficiency, significant cost reductions, and a stronger competitive position in the market.
20-30%
Energy Savings
Intelligent control and demand-side management identify and eliminate waste, leading to substantial reductions in energy consumption.
15-25%
Maintenance Costs
Predictive maintenance capabilities minimize unplanned downtime and extend the operational lifespan of critical assets, significantly cutting costs.
10-15%
Increased Uptime
Proactive issue identification and faster fault resolution lead to minimized production interruptions, boosting overall productivity.
99%
Enhanced Quality
Consistent environmental conditions and real-time process parameter monitoring ensure higher product quality and reduced reworks.
Compliance
Regulatory Adherence
Automated data collection and reporting simplify compliance with stringent environmental and safety regulations, reducing risks.
Coca Cola Hellenic Bottling Company
Coca-Cola Hellenic Bottling Company GmbH / Softdrinks and Römerquelle, Natural Mineral Water, Food & Beverages, 1 production site in Austria, Edelstal
Customer Situation/ Objectives
- Implementation of the scalable and flexible energy management system SIMATIC Energy Manager as a tool for energy data acquisition, processing and reporting.
- Creation of uniform energy reports in a short period of time
- Automatic acquisition of energy and consumption data easily via different interfaces
- Scalable and flexible system for energy management according to ISO 50001
Customer Benefit
- More flexible energy reporting (approx. 1 hour for report adjustment, previously 1 week)
- Simple implementation of new meters or data interfaces with just a few clicks
- Savings potential by integrating six high-pressure compressors in the compressed air network into the system
“With SIMATIC Energy Manager, we have a good starting point for defining savings targets and proving the cost-effectiveness of efficiency measures in the water and energy sector.”
Digital operations advantages
Ready for the Future
due to latest products and technology
All out of one hand
thanks to big product portfolio
Cybersecurity integrated
for secure operation incl. remote access
Efficient engineering
within one Framework for the whole Automation Tasks
Energy Efficiency
reliable specialist of the energy efficiency in pump and fan applications
Cost savings
seamless switch-over due to redundant systems for no data loss