Jens Fröhlich
Principal Consultant Operations – Portfolio Management MEDTEC
Digital manufacturing needs more than just technology – it needs collaboration. Learn in this blog post how DMG MORI, Tulip, and KUMAVISION are jointly creating consistent data structures, networking processes, and future-proofing production.
In modern manufacturing, whether e.g. in the Medical Technology or by Mechanical engineering / plant engineering, is a consistent data structure from the machine (shop floor) to the finished product Crucial. This means that all production data – from machine sensors and process parameters to quality controls – flow seamlessly into the central IT systems. Such end-to-end data integration eliminates isolated solutions and data silos, creates real-time transparency and seamless traceability, and provides companies significant competitive advantages.
In the following, we will examine how the partnership between DMG MORI, Tulip and KUMAVISION makes this possible and what advantages this offers, particularly for the medical technology and mechanical/plant engineering industries.
DMG MORI, Tulip and KUMAVISION – the dream team for digital manufacturing
How can such a consistent data structure be achieved? A current example is provided by... Partnership between DMG MORI, Tulip and KUMAVISIONHere, state-of-the-art machinery and a flexible MES platform meet a proven ERP industry solution:
- DMG MORI – one of the world's leading machine tool manufacturers – relies on the modular MES software Tulip, to digitally network its machines. Tulip is a No-Code Manufacturing Execution System (MES), which centrally controls and optimizes production processes by Real-time data Data from all areas of production is captured and managed. Machines, devices, and sensors can be directly connected via open interfaces (drivers, APIs, etc.). Authorized key users can even build their own apps with Tulip without programming knowledge to digitize and adapt processes on-site – making production more transparent, efficient, and flexible.
- KUMAVISION However, he is a specialist for ERP (Enterprise Resource Planning) software based on Microsoft Dynamics. 365 Business Central. As a Microsoft partner, KUMAVISION brings deep insights. Industry expertise one and delivers pre-configured ERP industry solutions (e.g., for medical technology, manufacturing, mechanical/plant engineering, trade, and project planning). This ERP system manages orders, bills of materials, inventory, quality assurance, and much more – in other words, the commercial and logistical processes within the company.
The integration of Tulip MES and the KUMAVISION ERP solution creates a seamless overall solution: Shop floor data and business processes seamlessly integrate. Production data from Tulip flows directly into the ERP system, while ERP order and bill of materials data are automatically available in the MES. DMG MORI and KUMAVISION impressively demonstrated this seamless integration during the “Digital Morning Coffee” event. – a joint webinar series. There, it was demonstrated live how Tulip can be integrated into the ERP system to directly connect shop floor data with business processes.
This integration requires setting new standards in transparency, efficiency and control of manufacturing. In other words: The interplay of DMG MORI's modular Tulip MES solution and KUMAVISION's ERP software answers the challenges mentioned at the beginning and opens up completely new possibilities for sustainable digitalization.
Practical advantages of MES-ERP integration
Let's talk specifically about the Advantages of the integrated approach – especially when Process parameters or important manufacturing data exchanged between MES and ERP. will need to be done. Some of the potential benefits have already been mentioned; here is an overview of the most important aspects:
- No duplicate entries, fewer errors: For example, if a machine process parameters When a value (such as torque or temperature) is measured, Tulip automatically transfers it to the system. The value is then simultaneously available in the ERP system via the interface – eliminating the need for manual entry or recording. This saves time and prevents transmission errors.
For example: During a quality inspection, all relevant measurement data can be recorded digitally and stored in the ERP system. The inspector no longer needs to ask "Which parameters should I save during quality control?“– the integrated solution ensures that all The required test data is automatically saved in the correct location. This makes production a step-by-step process. paperless, and employees on the line always receive the right information at the right time and in the right place.
- Real-time transparency and monitoring: Managers and employees in the production environment see in real time what is happening on the shop floorThe MES reports information such as the progress of a production order or machine status to the ERP system. This allows a control center to immediately see whether a customer order is proceeding as planned or if there are any bottlenecks. The question "What is the status of the customer order and can we meet the delivery date?" can be answered at any time with a single click. All departments – from purchasing and production to administration – work with the same up-to-date data; delays and discrepancies in information are a thing of the past.
- Traceability and quality assurance: In industries like medical technology, complete documentation is legally required (keyword: MDR, FDA, ISO 13485). By linking MES and ERP systems, every component and every process step becomes automatically traceable. Tulip, for example, can create a traceable record for every manufactured medical device. electronic manufacturing data set a Electronic Device History Record (eDHR) This generates a comprehensive record containing all process parameters, tests, and approvals. This information is centrally located in the ERP system and readily available for retrieval – for audits, certifications, or in the event of recalls. Even in the electrical industry, where serial numbers and batches must be tracked, the integrated solution ensures that everything is documented, from the component to the finished product. Quality Control It also benefits: Manufacturing defects can be detected and analyzed more quickly, as MES data (e.g. deviations in measured values) are directly linked to ERP data (e.g. affected batches and deliveries).
- Increased efficiency and productivity: When manufacturing cells are eliminated and processes are fully digital from end to end, productivity increases noticeably. Manual data entry Or the search for information is eliminated – employees can concentrate on value-adding activities. The combination of ERP and MES data also enables optimal resource utilization: machines, materials, and personnel are used more efficiently. Impressive results have already been achieved in practice through such integration projects.
Application examples: Medical technology and electronics, and mechanical/plant engineering
Finally, let's take a look at... exemplified by two industries, in which the integration of Tulip MES and KUMAVISION-ERP creates particular added value:
Medical Technology
Manufacturers of medical devices operate in a highly regulated environmentRegulations such as the EU Medical Device Regulation (MDR), ISO 13485, UDI or FDA regulations require a detailed documentation Every manufacturing step. An integrated MES-ERP solution greatly simplifies this: All production steps – from assembly and sterilization to final inspection – are digitally recorded. Tulip guides the operator through standardized work instructions and collects all relevant process parameters (e.g., torques, temperature curves, test results). This data flows automatically into the industry-specific ERP solution medtec. 365 a where they are linked to bills of materials, serial numbers and batch information. Result: The Device History Record is generated automatically in the background without any additional effort. In the event of an audit request, the company can prove at the touch of a button which device was manufactured with which components, settings, and test protocols. Also, the Batch traceability In the event of a field recall, the process is drastically simplified. Furthermore, quality managers gain early insight into trends: If an unusually high number of rework or limit deviations occur in a production batch, this is immediately visible in the real-time dashboards. Overall, the seamless integration in medical technology therefore ensures not only efficiency, but above all, Process reliability and compliance – an invaluable advantage in this industry.
Electrical engineering (electronics manufacturing)
The electrical and electronics manufacturing industry faces the challenge of high quantities at the same time high variety of variants to produce flawlessly. This is where the Flexibility and Usability The Tulip MES platform plays a major role. Assembly steps can be mapped as digital workflows without any programming effort and quickly adapted to product changes. Employees at assembly stations see the current work instructions on tablets and are guided through the process step by step. Tulip records every action and every measurement: from tightening torques on a circuit board assembly to test voltages or optical inspections. Integration with the ERP system This ensures that, for example, assembly data is reconciled with the bills of materials in the ERP system and that consumables are automatically restocked. Conversely, the ERP system can directly transfer production orders, component batches, and inspection specifications to Tulip – all relevant information is digitally available to the production employee; nothing needs to be painstakingly searched for. The result is significantly fewer errors in manufacturing (up to 60% fewer assembly errors) and a higher productivityEspecially in electronics, where margins are under cost pressure, every avoided error pays off. Furthermore, data integration improves... lead timesFor example, when an assembly is reported as complete, the ERP system can immediately initiate the next production step or shipping without manual feedback. Service and maintenance data from the machines (e.g., from the Tulip) are also processed. Machine MonitoringThis data can be transferred to the ERP system to plan preventive maintenance – reducing downtime. All of this gives companies in electronics manufacturing a significant advantage in terms of speed and quality.
Mechanical / Plant Engineering
In mechanical and plant engineering, due to the early start of production, initial components of the overall system are often manufactured even before the design phase is complete. The entire manufacturing process is characterized by frequent changes (growing bills of materials) and requires up-to-date information and drawing data at each workstation. This is achieved through the integration of the industry solution factory.365 familiar with the direct control of workplaces via Tulip The permanent current design status Having paper-based design drawings readily available at workstations and the need to collect and exchange them in production is a thing of the past. Furthermore, the current production status is always visible and can be taken into account when implementing any design changes. This significantly reduces the workload. greater flexibility, process reliability and speed This is made possible during the manufacturing and unavoidable change process. At the same time, work is always carried out using the latest drawing versions to avoid errors.
Conclusion: The future of manufacturing – networked, transparent, efficient
The end-to-end digitalization of manufacturing – from the sensor of the machine tool to the financial accounting in the ERP system – is no longer a future dream, but achievable and extremely beneficialThe partnership between DMG MORI and KUMAVISION with Tulip exemplifies how to create a MES and ERP become the integrated nervous system of production can connect. The advantages range from fewer errors, higher Productivity and better Quality to Compliance-Security and a more agile response to customer requests.
It is also important that ProcedureInstead of "Big Bang" projects, a iterative approachIn the “Digital Morning Coffee” segment, it was emphasized that small steps should be taken. Proof-of-Value-Start projects and then expand them gradually. This minimizes risks and allows the system to grow agilely with requirements. Every successful integration of a subprocess delivers immediate added value and can subsequently be scaled.
Ultimately, investing in consistent data structures in manufacturing pays off immediately: companies gain Real-time insights by integrating MES-ERP into their production processes, companies can make more informed decisions and optimally manage their entire value chain. In a time when supply chains, quality requirements, and cost pressures are becoming increasingly complex, MES-ERP integration is therefore more of a success factor than ever before. the digital dream team for a future-proof industry.
