Automated Process Transfers with MES-SCADA-Integration

Sekisui Alveo is a leading European manufacturer of high-quality cross-linked and non-cross-linked foams used across a wide range of applications, including construction and insulation, packaging, vehicle interiors, and sports flooring.

Initial Situation & Background

At several locations, Sekisui Alveo operates highly advanced production machines whose operational specifications are controlled in real time based on defined process parameters. These parameters were originally recorded digitally via a proprietary, tailor-made software solution and automatically transferred to the machines.

In parallel, the company centrally manages its value chain using the MES HYDRA. Step by step, all existing standalone solutions are to be replaced and fully integrated into the MES. In addition, Sekisui Alveo operates one SCADA system per production hall, which stores machine parameters and historical measurement data.

Goal

The goal of the project was to completely replace the existing in-house development and to centralise the management of all process parameters directly within the MES HYDRA.

This was intended to achieve the following:

• Standardisation of product and process parameters within the MES
• Automatic and error-free transfer of recipes to production machines
• Creation of a uniform, stable, and future-proof system architecture
• More efficient and consistent production control

This represents a clear step towards Industry 4.0, reducing manual activities and ensuring long-term quality standards.

Approach & MEGLA-Solution

We developed a scalable solution that reliably transfers product and process parameters from the MES HYDRA to the SCADA system.

For communication, Sekisui Alveo uses MPDV’s Digital Edge Computing (DEC). This technology is primarily designed for static data acquisition and was initially unable to meet the complex requirements of process parameter transmission.

We closed this gap by developing customised DEC Blades, intelligent software modules that provide extended logic for production control.

Functionality of the DEC Blades

• Transfer of the next operation, including material, order number, and product information
• Provision of relevant process parameters such as temperature, torque, or pressure
• Display of comprehensive previews for machine operators, enabling proactive preparation
• Ensuring consistent, standardised machine parameters without manual deviations
• Storage of changes resulting from manual intervention; in the future, machines are intended to operate in a fully tamper-proof manner, with changes permitted only via authorised process owners

The result is a seamless data flow between MES, SCADA, and machines, fully integrated and automated.

Results & Benefits

• Replacement of the proprietary solution: Modernisation of the IT and production landscape through consistent, MES-based processes.
• Centralised parameter management in the MES: Uniform quality standards and reliable recipes for each product, while ensuring consistently high product quality.
• Reduced manual effort: Lower susceptibility to errors, faster production processes, and increased efficiency.
• Homogeneous system architecture: A future-proof foundation for further digitalisation, analytics, and automation.
• Transparent and proactive production planning: Clear operation information, better preparation for machine operators, fewer downtimes, and optimised changeovers.

Customer Feedback

Sencer Akcan, Lead Digital Transformation at Sekisui Alveo:

"Thanks to the MEGLA solution, we are now operating more efficiently while also benefiting from a streamlined system landscape. As less manual intervention is required, we are able to ensure a consistently high level of product quality.”"