Stop retyping shop floor numbers into SAP: an interactive integration demo
Machines, an edge gateway, a message broker, MES, quality, warehouse, ERP and a plant dashboard, laid out by level. Release an order and follow it to the machine, watch counts flow back up, cut the network and see nothing lost, then put a batch on hold and watch dispatch blocked.
Every number, ID and event in this demo is simulated to show how the system behaves. None of it is customer data or a measured result.
What you are looking at
- Order from ERP: a production order travels from ERP through MES and the broker to the line.
- Order on the machine: it appears on the line HMI with its recipe; nobody typed it.
- Counts flow up: machine counts reach MES, OEE reaches the dashboard, and MES confirms yield to ERP.
- Network outage: the edge stores messages while the link is down and replays them in order after.
- Quality hold: the quality system blocks a batch in the warehouse and in ERP stock.
- Stock updated: goods receipt flows from MES to the warehouse system and ERP.
How this maps to a real project
We start by listing the numbers your people carry between systems today, then connect the ones that cost the most time or cause the most errors first, using the standard interfaces of the systems you already run.
You own the integration code and the documentation, so your team or another can maintain it.
From real projects
Our RFID and QR based vendor material system syncs with SAP in real time, covering vendor materials worth more than ₹20,000 crore (about US$2.4 billion) moved every day.
Company reported project figure, not independently audited, not a promise for another site.
Questions
How do shop floor machines connect to SAP or another ERP?
Machine signals are collected at the edge from PLCs over protocols such as OPC UA, published to a message broker, used by the MES, and confirmed to the ERP through its standard interfaces. The ERP stays the system of record.
What happens to data when the network goes down?
The edge gateway stores messages locally while the link is down, machines keep running, and the stored messages are replayed in order when the link returns, so no counts are lost.
Why use a message broker between systems?
With a broker each system publishes and subscribes to topics instead of being wired to every other system, so adding a dashboard or a new line does not mean rebuilding point to point links.
Is the data in this demo real?
No. The order, counts, topics and messages are illustrative, to show how the integration behaves. They are not customer data.
Why does the demo ask for my name and email?
So an engineer can follow up if you want to map your own systems. The explanation on this page is open to everyone; only the interactive view needs the form, once for all six demos.
Free scoping call. We start with one line, never change your machine logic, and you own the code and the data.