Tight Integration of Process Control with ERP

Overview:

For a new built multi purpose batch plant the DCS with batch control was linked to the ERP-system of the company to ensure consistent and up-to-date data in all systems. As part of the engineering project of the plant the part process control using a standard DCS with the manufacturers batch extension was configured to meet the needs resulting from the task to exchange data and information with the company-wide used ERP-system. Nevertheless a direct link between DCS and ERP-system could not be established due to misfit of data models. Therefore a „Middleware“ was configured and programmed. The Middleware takes relevant material information from the ERP-system and sends it to the batch control system, takes master recipes from the batch control system and creates planning recipes within the ERP-system, takes orders from the ERP and generates control recipes within the batch control system, and reads current data from the DCS about process status and material consumption and production and creates messages for the ERP. The Middleware translates between DCS and ERP generating fast and reliable information-update in all systems and comprehensive documentation of the production process with low personnel efforts.