Aquatherm, a German leader in manufacturing plastic piping systems, is known for its environmentally friendly polypropylene products. These products are widely used in over 70 countries, reinforcing the company’s commitment to sustainable practices and global climate protection goals. With its workforce of approximately 500 employees, aquatherm has long been dedicated to operational excellence. However, growing demands highlighted inefficiencies, such as reliance on manual data entry, that needed addressing to maintain and improve their high standards.
To tackle these challenges, aquatherm implemented SAP Digital Manufacturing, a Manufacturing Execution System (MES) that leverages real-time data and analytics to enhance production processes. This decision followed their adoption of SAP S/4HANA Cloud as their core business system in 2022. Despite this foundational digital transformation, manual operations persisted, leading to inefficiencies that needed rectification. The new system promised to deliver a seamless and efficient data exchange, eliminating manual inputs and significantly optimizing manufacturing operations.
Optimization Through Real-Time Data
SAP Digital Manufacturing’s Implementation
The initial phase of integrating SAP Digital Manufacturing into aquatherm’s workflow began in one of their production areas. This phase was crucial as it provided vital insights into machine performance and identified bottlenecks that had previously gone unnoticed. By integrating SAP S/4HANA Cloud with SAP Digital Manufacturing, aquatherm achieved seamless data exchange across their systems, which substantially reduced downtime and enhanced operational efficiency.
Patrick Keller, SAP Technical Consultant at aquatherm, emphasized how automation played a pivotal role in minimizing manual data entry. This not only reduced the frequency of PC-based tasks by an impressive 90% but also significantly improved data quality. This automation liberated valuable time for machine operators, allowing them to focus on more critical aspects of production. The result was an enhanced production environment where real-time data provided accurate and actionable insights for decision-making.
Challenges and Solutions in Data Standardization
Implementing the new system was not without its challenges. One major obstacle involved sourcing accurate data from various machine manufacturers that adhered to different standards. To surmount this, aquatherm collaborated closely with SAP and BA Business Advice GmbH to develop standardized templates for their machines. This adherence to SAP’s fit-to-standard implementation approach was essential in avoiding extensive custom developments that could complicate existing processes.
The standardized templates allowed the company to maintain its current production methodologies while seamlessly integrating the new system. After a comprehensive three-month proof of concept, the full implementation was completed in just six months. This expedited timeline was a testament to the efficiency of the chosen approach and the collaborative efforts of all parties involved. The successful implementation underscored the feasibility and effectiveness of the system in enhancing aquatherm’s production capabilities.
Future Expansions and Analytics
Extending SAP Digital Manufacturing’s Reach
Looking ahead, aquatherm plans to expand the deployment of SAP Digital Manufacturing across all production areas. This expansion is set to further refine production control and bolster data exchanges between SAP S/4HANA Cloud and SAP Digital Manufacturing. This strategic extension aims to harness even greater efficiencies and improve operational transparency throughout the production lifecycle. By extending the use of SAP’s robust data analytics tools, aquatherm seeks to leverage insights that will drive continuous improvements.
The future phase also involves the utilization of SAP Digital Manufacturing Cloud for Analytics. This will complement the existing systems by providing deeper analytical capabilities, enhancing the overall decision-making process. Additionally, integrating SAP Analytics Cloud and the Production Connector will facilitate smoother data exchanges with industry-specific sources. These technological advancements are expected to further streamline operations and provide an integrated approach to data management and analysis.
Laying the Groundwork for Data Analytics and AI
Aquatherm, a German leader in plastic piping systems, stands out for its eco-friendly polypropylene products, which are used in over 70 countries. This underscores the company’s dedication to sustainable practices and global climate protection. With around 500 employees, aquatherm has consistently aimed for operational excellence. However, increasing demands revealed inefficiencies, such as a dependence on manual data entry, that needed to be addressed to maintain and enhance their high standards.
To address these challenges, aquatherm integrated SAP Digital Manufacturing, a Manufacturing Execution System (MES) that uses real-time data and analytics to improve production processes. This move came after they adopted SAP S/4HANA Cloud as their main business system in 2022. Despite this first step in digital transformation, manual operations remained, resulting in inefficiencies. The new system aimed to ensure seamless and efficient data exchange, eradicating the need for manual inputs and significantly boosting manufacturing operations. This modernization effort reflects aquatherm’s commitment to innovation and efficiency.
