home / case studies / European food processing group (composite)
IT/OT Convergence

MES-to-ERP Integration and End-to-End Production Traceability

We integrated shop-floor MES and line systems with the ERP to provide real-time production orders, material consumption and lot genealogy. Recalls and audits that used to take days are now answered in minutes.

European food processing group (composite) · IT/OT Convergence

MES-to-ERP Integration and End-to-End Production Traceability

Challenge

Heterogeneous line equipment and strict uptime requirements. We rolled out line by line during planned changeovers and kept a paper fallback until each line passed a mock recall test.

Approach

We implemented an integration layer that exchanges production orders, bills of materials, consumption and yield data between ERP and MES using ISA-95 (B2MML) message models. Line-level data from PLCs and scales is collected at the edge and linked to lot and batch IDs. A traceability service builds forward and backward genealogy graphs (raw material lot to finished pallet). Operator tablets replace paper batch records with guided electronic workflows.

Outcome

Mock recalls answered in minutes rather than days Real-time inventory and consumption postings Illustratively ~40–60% less time spent on batch record review Fewer data-entry errors through electronic batch records Stronger audit readiness for food safety standards

✓Mock recalls answered in minutes rather than days
✓Real-time inventory and consumption postings
~40–60%Illustratively less time spent on batch record review

Problem solved

Paper batch records and delayed ERP postings meant inventory was inaccurate and traceability exercises required pulling paper files from several sites.

What we built

We implemented an integration layer that exchanges production orders, bills of materials, consumption and yield data between ERP and MES using ISA-95 (B2MML) message models. Line-level data from PLCs and scales is collected at the edge and linked to lot and batch IDs. A traceability service builds forward and backward genealogy graphs (raw material lot to finished pallet). Operator tablets replace paper batch records with guided electronic workflows.

Benefits

Mock recalls answered in minutes rather than days Real-time inventory and consumption postings Illustratively ~40–60% less time spent on batch record review Fewer data-entry errors through electronic batch records Stronger audit readiness for food safety standards

MESERPISA-95B2MMLPLCGenealogy graphsElectronic batch records

Talk to us