Manage highly complex, multi-product batch manufacturing with numerous recipes and customer-specific requirements.
Ensure seamless integration between planning, production, and control systems to handle make-to-order production efficiently.
Increase transparency, usability, and real-time visibility for operators despite process complexity.
Optimize plant utilization, meet strict delivery deadlines, and reduce manual intervention and errors.
Implementation and upgrade of a Manufacturing Execution System (MES) – Siemens Opcenter Execution Process (Opcenter EX PR) integrated with:
SAP ERP system (material management, order creation)
Existing SIMATIC PCS 7 process control system with SIMATIC Batch (batch execution)
Key functionalities:
Automatic generation of digital production (batch) cards from SAP order data.
Synchronization of production data, recipes, materials, and KPIs across ERP, MES, and control system.
Integration of quality data and OEE dashboards for KPI monitoring.
Visualization of plant processes and operator guidance in real time.
Orders generated in SAP are processed in MES, which orchestrates execution in the control system and feeds data back to SAP.
“Our plant runs continuously at very high utilization. We need a highly available architecture and reliable technology. [...] This ongoing support enables us to continuously optimize production.”
Marco Richter, Technical Manager at Evonik in Weiterstadt
Increased process efficiency and plant utilization through synchronized production data
Improved First Pass Quality (FPQ) and reduced production errors
Enhanced transparency and real-time visibility for planners and operators
Reduced manual activities, enabling operators to focus on process monitoring
Reliable, consistent data across systems, preventing data loss and improving decision-making
Next steps
Further digitalization of production processes toward largely automated, end-to-end digital operations.
Continuous optimization and functional expansion of MES and automation systems.
Ongoing improvement of KPIs and production efficiency using integrated data and dashboards.
Evonik‘s Oil Additives business line is one of the world‘s leading suppliers of viscosity and flow improvers. At its Weiterstadt site, the company produces a wide variety of VISCOPLEX® products.
