Hansa-Flex – MES Pro

Initial situation

• Workers take the relevant production parameters from printed production orders
• Searching paper documents for important information is laborious and inefficient
• Workers cannot easily check whether all components required for a production order are present; this can lead to missing, surplus or incorrect parts
• Important details such as technical drawings or complaints are only available in SAP and therefore awkward for workers to access
• Set-up and processing times are recorded manually in SAP, which often leads to inaccuracies (actual time is set to target time)
• Produced quantities are confirmed manually in SAP
• Workers cannot see immediately how many hoses have actually been crimped
• A lack of insight into the future use of the components currently in use leads to inefficiencies in material handling

Challenge

• Develop an intuitive interface that shows all relevant data without overwhelming the user
• Make the component check easier by displaying images of all required components, so that completeness and correctness are ensured
• Simplify the confirmation of times and produced quantities in order to reduce errors and increase accuracy and transparency
• Ensure that complaints are confirmed, so that workers are aware of them before continuing
• Implement fail-safe time recording that prevents data loss caused by app crashes or reloads
• Detect incorrect crimping counts in order to improve product quality and minimise errors
• Provide insight into future component use, so that frequently needed components can stay at the workstation instead of being returned to the warehouse unnecessarily

Solution

• User-friendly SAP Fiori app: A minimalist, intuitive layout for easy access to all necessary data
• Integrated key information: Technical drawings, component images and complaints directly in the app
• Display of component images: The app shows images of all components required for the production order, so that workers can easily check before production starts whether all parts are present and correct
• Mandatory confirmation of complaints: Complaints are displayed first and must be confirmed by the worker before work can continue
• Automatic time confirmation: Workers do not have to record their time manually, which reduces errors
• Regular time backup: The elapsed time is saved to SAP regularly, so that work can continue seamlessly after an app crash or reload
• Real-time crimping data: Live data from the hose presses is displayed in the app, with the actual crimping count next to the target value
• Quality notifications: Workers are notified when the actual crimping count deviates from the target of the production order; this increases accuracy and prevents complaints
• Insight into future component use: The app shows what the components currently in use will be needed for in future. Workers can thus see whether material such as hoses will be needed again later in the day. This avoids unnecessary returns to the warehouse and increases efficiency

Process

Workstation

The workstation is equipped with an industrial workbench on which all tools for crimping the hoses are at hand. A touchscreen monitor mounted at the workstation shows the SAP Fiori app MES Pro and presents all relevant production data to the workers in a clear and structured way. A second monitor is intended for monitoring and setting up the hose press and provides control and transparency over machine operation in real time. The hose press itself stands directly next to the workers and enables a smooth, efficient flow between digital guidance and practical execution.

Architecture

Display and confirmation of the production order

1. The SAP Fiori app requests the information on the production order from the SAP Private Cloud.
2. The SAP Private Cloud retrieves images and documents from the archive and document server and from the file storage for product images.
3. The archive and document server and the image storage deliver all relevant data to the SAP Private Cloud.
4. The SAP Private Cloud sends the information on the production order to the SAP Fiori app.
5. The SAP Fiori app confirms the produced quantity and the elapsed set-up and processing time to the SAP Private Cloud.

Time backup

1. The SAP Fiori app saves the elapsed set-up and processing time to the SAP Private Cloud every 30 seconds.
2. After an app crash or reload, the SAP Fiori app retrieves the saved time and continues processing seamlessly.

Live data from the hose press

1. The hose press sends real-time data on the production order to the SAP Private Cloud via TCP.
2. The SAP Private Cloud stores the crimping data, including the order’s crimping counter.
3. The SAP Private Cloud transmits crimping updates to the SAP Fiori app in real time via ABAP Push Channel.
4. The SAP Fiori app displays the order’s current crimping count in real time and warns workers during confirmation if the actual count deviates from the target.