Manufacturing IT/OT

Using Manufacturing Business Intelligence to Achieve Operational Excellence

Shop Floor to Top Floor, MES for the Digital Manufacturing Enterprise

The “Digital Enterprise” transformation today is fostered by various technologies bridging the Information Technology/Operational Technology (IT/OT) landscape. From IIOT, Big Data/Analytics, along with Digital Twining, these technologies provide an enhanced level of business intelligence and performance delivering operational excellence. A typical shop floor is inundated with the influx of data, in a myriad of formats, generated by multifarious devices and equipment. For these manufacturing enterprises, there is significant value in unlocking hidden functionality from the data. The lack of current technology, holistic and tightly integrated MES system to provide immediate and accurate prescriptive actionable intelligence can take a toll on productivity, even pushing shop floors into operational instability. In times of such rapid transformation, RTS’s approach toward MES begins with aligning business goals with shop floor KPI’s and actionable intelligence. Enterprise Resource Planning + MES When real-time shop floor data is tightly integrated with business information, a company has the manufacturing business intelligence to deliver operational excellence. Manufacturing IT consulting for your business should include an integrated approach that covers off such vital areas as quality, maintenance, production planning, and more.

Imagine leveraging your existing shop-floor control systems via a standardized bi-directional connector, such as ezConnect, to all your production assets. The result is real-time, role based, contextualized visibility to information, which means you can:

  • Align your ERP and manufacturing operations with your business objectives
  • Identify and measure results of continuous improvement and lean initiatives
  • Improve plant operational efficiency and increase throughput while monitoring bottlenecks
  • Increase agility and responsiveness to customer demands
  • Increase plant utilization via overall equipment effectiveness (OEE)
  • Better scheduling and adherence to production plans

Industry 4.0 – IIoT (Industrial Internet of Things) – “The Future is Smart”

The transformation of the industrial sector has begun.  Whether it's called Industry 4.0 or IIoT, companies have begun to use available technologies to revamp their business model.

For companies with the right mindset, Industry 4.0/IIoT platforms and technologies will open up major opportunities for improved asset performance along with increased operational efficiency, and completely new ways of offering value to customers. An example of Industry 4.0/IIoT is a system that can predict failures and trigger maintenance processes autonomously or self-organized logistics within the four walls of the plant with autonomous vehicles reacting to unexpected changes in production.

The world of production will become more and more networked until everything is connected and exchanging data with everything else. This also means that the complexity of manufacturing and supply networks will grow enormously. Today networks and processes have so far been mostly limited to one factory, in the future factories will communicate with each other. In fact, RTS is currently working on multi-plant production communication within the automotive space.

SAP MES and HANA for Manufacturing Big Data

This process of examining large and varied data sets from production, quality, shipping, productivity, etc -- i.e., big data -- to uncover hidden patterns, unknown correlations, manufacturing anomalies and other useful information that can help organizations make more-informed business decisions.

SAP HANA combines database, data processing, and application platform capabilities in-memory. The platform provides libraries for predictive, planning, text processing, spatial, and business analytics. SAP MII (V15) provides real time plant floor data to HANA, enabling manufacturing data to be part of the in-memory analytics.

The large data set can drive Predictive Analytics, such as the probability of different future outcomes (think optimal time to do asset maintenance) based on a look forward production plan.

The last component may be Prescriptive Analytics, that is to integrate our tried-and-true predictive models into our repeatable processes to yield desired outcomes. An automated risk reduction system based on real-time data received from sensors on the shop floor assets.


SAP HANA as the manufacturing operational data store (ODS) platform for building and deploying real-time, integrated business applications and analytics.

Why work with RTS?

After 25 years in the manufacturing shop floor space, we have developed core competencies:

  • Diverse industry expertise, Automotive, Plastics, Milling, Chemical, Mining, Brewing, Pharmaceutical, Metal
  • Shop floor data collection and asset connectivity expertise
  • Large selection of pre-built SAP MES templates
  • Integration of disparate shop floor data silos and SAP ERP experience