PHOENIX CONTACT Enhances Manufacturing Efficiency with HYDRA MES and SAP Integration
Customer Company Size
Large Corporate
Region
- Europe
- America
- Asia
Country
- Germany
- China
- Poland
- United States
Product
- HYDRA Manufacturing Execution System
- SAP ERP System
Tech Stack
- Windows Server
- ORACLE Database
- SAP Interfaces
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Productivity Improvements
- Cost Savings
- Customer Satisfaction
Technology Category
- Functional Applications - Manufacturing Execution Systems (MES)
- Functional Applications - Enterprise Resource Planning Systems (ERP)
Applicable Industries
- Electronics
- Equipment & Machinery
Applicable Functions
- Process Manufacturing
- Quality Assurance
Use Cases
- Manufacturing System Automation
- Predictive Maintenance
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
About The Customer
PHOENIX CONTACT is a global market leader in the field of electrical engineering, electronics, and automation. With a workforce of 17,400 employees, the company is headquartered in Blomberg, North Rhine-Westphalia, and operates various production sites and sales offices worldwide. PHOENIX CONTACT is known for its high level of vertical manufacturing, producing a wide range of product components and system solutions for the tooling and processing sector, as well as other industries. Their product offerings include PCB, special-purpose and terminal blocks, cable and plug connectors, and automation devices based on Ethernet and Wireless technologies. The company is committed to innovation and excellence in manufacturing, making it a prominent player in the global market.
The Challenge
PHOENIX CONTACT faced the challenge of managing and efficiently controlling a vast array of data derived from complex multi-staged manufacturing processes. The company needed a solution that could provide higher transparency in production, improve productivity, and enhance the quality of data supplied by their ERP system, SAP. Additionally, they required a system that could detect machine standstills and provide statistics to optimize machine and tooling availability. The challenge was further compounded by the need to ensure the availability of all required resources for machines at the start of production, necessitating timely information and efficient data transmission to injection molding machines.
The Solution
To address the challenges, PHOENIX CONTACT implemented the HYDRA Manufacturing Execution System (MES) by MPDV across various locations in Germany and Poland, with pilot projects in China and the USA. The MES solution provided higher transparency in production, improved productivity, and enhanced data quality from the SAP ERP system. HYDRA supported actual data monitoring with detailed feedback, enabling the detection of machine standstills and the implementation of measures to optimize machine and tooling availability. A fixed three-day production plan was generated by combining HYDRA Shop Floor Scheduling with the Tool & Resource Management module, ensuring the availability of all required resources at the start of production. The DNC module simplified the transmission of configuration data to injection molding machines, while important processing parameters were continually recorded and monitored. HYDRA also served as a CAQ subsystem to collect, control, and measure values for further processing in SAP QM. The system's KPIs allowed responsible personnel to target monitoring processes and initiate improvements, leading to cost reductions and proportional detection among departments.
Operational Impact
Quantitative Benefit
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