How companies are really making their production more efficient
Shop floor digitization is considered one of the most challenging tasks of industrial transformation.
Because hardly any other area in the company combines so many different requirements:
- Machines and systems of different generations
- heterogeneous IT systems such as ERP, MES or databases
- High demands on mobility and usability directly on the line
- Complex, often very specific production processes
Many companies therefore initially rely on the standard functions of their existing systems – for example in the ERP or SAP environment. However, it quickly becomes clear, especially on the store floor, that standard solutions often reach their limits here.
Individual process requirements, integration effort and long development cycles mean that many digitalization projects progress more slowly than planned or are not implemented at all.
Yet there is enormous potential in production in particular.
The underestimated lever: process digitization instead of new machines
In many manufacturing companies, Overall Equipment Effectiveness (OEE) averages between 60 and 65 percent. World-class production, on the other hand, achieves values of 85 percent and more. The difference is often not due to new machines, but to better processes, faster response times and greater transparency.
Even an increase in OEE from 65% to 75% can increase output by over 15% – without additional lines or shifts. An example illustrates the economic dimension:
In a production facility with three production lines and opportunity costs of around €500 per hour, an improvement of 10 percentage points in OEE can generate an additional contribution margin of around €2 million per year. The key to this lies in the systematic digitalization of store floor processes.
Why store floor digitization is so difficult
The reason is rarely a lack of data. Most production environments already have a variety of information sources: ERP systems such as SAP or other business solutions, machine controls and sensor technology, Excel lists and manual documentation, MES or IoT systems The real problem is rather the fragmentation of this information: Data is available in different systems, processes are sometimes controlled manually and improvement measures are difficult to evaluate systematically. In many companies, this results in a typical picture:
lots of reporting – but little operational controllability.
The platform approach: digitalization as an end-to-end process
Effective store floor digitalization therefore requires more than individual applications or isolated automation solutions. A platform that connects processes, systems and data is crucial. This is where the Simplifier digitalization platform comes in. It enables companies to digitize store floor processes quickly and integrate their existing system landscape at the same time.
Integration of heterogeneous production systems
One of the biggest challenges in production environments is the multitude of different systems and interfaces. Simplifier connects these worlds:
- Integration of common ERP systems such as SAP, Sage, ABAS, Dynamics or Oracle NetSuite
- Connection of machines via IIoT gateways or PLC adapters
- Standardization of different machine interfaces
- Integration of cloud services and data platforms
This creates a consistent database for production processes.
Fast implementation thanks to low-code
A decisive success factor for store floor projects is the speed of implementation. With low-code technology, applications can be developed five to ten times faster than with traditional programming. Visual development tools and process modeling are used instead of complex code. This means that specialist departments can also be actively involved in the further development of applications. This reduces dependencies on external development resources and increases the flexibility of the organization.
Transparency and continuous improvement
In addition to data collection, analysis plays a central role in process optimization. Simplifier supports companies with functions such as
- Real-time Pareto analyses to identify production losses
- Integration of the PDCA cycle (Plan-Do-Check-Act)
- Support for lean methods such as KATA or Hoshin Kanri
This allows improvement measures to be systematically implemented and their impact to be measured.
From the pilot phase to the rollout
Successful store floor digitization usually follows a clearly structured approach:
- Analysis and evaluation of existing processes
- Pilot projects for selected use cases
- Scaling successful solutions to other production areas
Simplifier supports this approach with best-practice templates, training programs and a structured implementation model. Many projects show a rapid economic effect:
The payback period for store floor digitization is often just three to six months.
Practical example from the industry
Machine manufacturer Hako is one example of how this approach works in practice. There, paper-based processes in production were gradually replaced by digital applications. The focus was not only on replacing manual documentation, but also on creating a scalable platform for future process digitization. Read more about this in the Industrieanzeiger and in Digital Manufacturing.
Conclusion: Rethinking digitization on the store floor
Store floor digitalization is complex – but its economic potential is enormous. Companies that systematically digitalize their production processes can not only create transparency, but also sustainably increase their efficiency. A platform strategy can reduce integration costs, shorten development cycles and support continuous improvement processes. This turns individual digitalization projects into a scalable basis for the production of the future.
