MES and ERP seamless battle: the number of synchronisation and integration methods

Still for ERP and MES system "chicken and duck" headache? Production plan to the shop floor to "disappear"? Inventory data in the financial and warehouse reconciliation between the accounts? Do not panic! Today we hand in hand to dismantle the seamless integration of the actual set of routines - specialising in data fights, incompatible protocols, to ensure that you do not take a detour from the needs of the landing!

I. Synchronisation of data: three mountains to break before "information silos" are addressed

​Ask yourself: Why do ERP and MES data never match?​
The answer is three words.each sings a different tuneERP with "order number", MES recognises "work order number"; ERP inventory counted by piece, workshop scanning code according to the batch - data can be synchronised! It is strange that the data can be synchronised!

​Three moves to break the game::
✓Die Hard Data Dictionary: Uniform field naming across the company (e.g. material coding rules:Category-Model-Batch), as unique as an ID card
✓format-strengthening constraint: JSON/XML to go, disable Excel manual table guide (a chestnut: date all use)yyyy-mm-dd hh:mm:ss(Format)
✓real time synchronisation engine::

  • ​incremental synchronisation: Transmit only change data (e.g. new orders), save 90% bandwidth
  • ​full synchronisation: Running batches in the early hours of the day, suitable for basic data (e.g. BOM lists)

lesson learnt through blood and tears: A factory was shut down due to ERP and MES unit inconsistency (kg vs. tonnes), and MES misjudged the lack of material -The data dictionary is the constitution of the production line!​

​Synchronisation Method Performance Comparison Table::

way (of life) Applicable Scenarios cutting edge exposures
​Real-time API​ Order placement, production reporting Second response, zero business delay Network fluctuation prone to packet loss
​Timed Batch Processing​ Inventory count, costing Carrying large amounts of data Delays of up to several hours
​message queue​ Equipment status monitoring automatic transmission of data when disconnected Additional middleware costs required

Second, the interface integration: choose the right "translator" less step on the pit of 80%

​Ask yourself: OPC UA, RESTful API, middleware... which one to use without rolling over?​
Look at the business scenarios!Choosing the wrong protocol is tantamount to letting Cantonese cooks listen to Shanxi's order.-ERP wildly issued commands, MES died on the spot

​Real-world four-choice::
1️⃣Direct connection to database(JDBC/ODBC):

  • Suitable for retrofitting older systems (e.g. direct read/write with SQL)
  • ​minefield: lock table risky, shop floor query fierce ERP card crash
    2️⃣API Hardcore(RESTful/SOAP):
  • New system preferred (as flexible as a Lego puzzle)
  • ​compulsory: HTTPS encryption + token authentication to prevent hackers from tampering with recipes
    3️⃣middleware bridge(MQ/Kafka):
  • Carry high concurrency magic weapon (500 devices at the same time to send data is not afraid of)
  • ​case (law): A car company uses MQTT to transmit device status, saving 60% in bandwidth.
    4️⃣Document ferry(CSV/FTP):
  • Dirt but it works! Ideal for small factories with limited budgets
  • ​constraint: high latency, don't use it for real-time scheduling

Developer Tweets: A pharmaceutical company used HTTP to transmit production parameters and had its formula tampered with by a blackmailer-Protocols not encrypted are the same as plants not locking their doors!​

Third, to avoid the pit of actual combat: did not go through the "torture" docking are paper tigers

​Ask yourself: what if development and testing are fine, and then crash as soon as you go live?​
​Missing a stress test is laying a mine!These three "penalties" must be meted out:

​⚡ Data consistency checks::

plaintextmake a copy of
Number of ERP shipments: 1000 pieces → Number of MES incoming shipments: 1000 pieces ✔️
Equipment speed value: 1500rpm → MES display value: 1500rpm ✔️
(The error exceeds ±0.5% and an alarm is issued immediately!)


​🛡️ Disaster Recovery Exercise::


    

  • Unplugging the network cable to verify the disconnect (key!)
    • 

  • Simulate server downtime with zero data loss after reboot
    
​🔥 Extreme pressure testing::
    • 

  • 500 devices to fill 100,000 pieces of data per second (CPU spiked to 90%+)
    • 

  • Deliberately pass dirty data (e.g. negative yield) to see if the system melts down
    • 





Overturning casesPV Plant Skips Pressure Test, MES Overwhelmed by Orders on the First Day of Go-Live -The laziness of testing is all the tears of production line downtime!​






Fourth, the personnel landing: again cattle system, people do not get up is scrap iron!


​Self-questioning: IT department tossed half a year, but the workshop moncler outlet store said "will not use"?​

​Training does not go anywhere, and the system becomes obsolete!Three tricks to get workers "hooked":


▶︎Poker Instruction Method::


    

  • Fault codes are printed in poker ("K of hearts = equipment overheating"), playing cards and remembering codes in the process
    • 

  • Scan the code to watch a short 3-minute video: teaching warehousemen to use PDA to scan code into the warehouse
    
▶︎"Everyone's got a problem" in action::
    
Production line intentionally buried wrong (such as material code less than one), who uncovered the prize red packet!
    
▶︎"Pass it on" certification::
    
Teacher with an apprentice → rewarding double working hours.Let skilled labour earn more!​
    • 





​And finally, something solid.MES-ERP docking, do not believe that "out of the box that is used" - you look at the Alcoda auto parts factory, hard to gnaw down the tool management module, the loss rate cut 20%. technology and then fancy, and ultimately to solve! The real problem on the production line. Remember.The pinnacle of systems integration is for the shop floor manager to throw away Excel and take the initiative to poke at the big screen Kanban!​

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