Automated Process Transfers

Greater efficiency, fewer errors, consistently high quality – automated process handovers as a key success factor in foam production

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:

• Product and process parameters are standardised and stored in the MES >reproducible quality across all sites
• Recipes are automatically and error-free transferred to the machines > less scrap and rework
• A uniform, stable, and future-proof system architecture is established > reduced maintenance and IT effort
• Production control becomes more efficient > shorter changeover times and higher machine availability

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
  • Operators can immediately see what comes next and start without further clarification
• Provision of relevant process parameters such as temperature, torque, or pressure
  • Manual data entry is elimiated and incorrect settings are avoided
• Display of comprehensive previews for machine operators, enabling proactive preparation
  • All process data is visible at an early stage, allowing better preparation and smoother handovers
• Ensuring consistent, standardised machine parameters without manual deviations
  • Each machine operates with the same approved parameters, ensuring stable product quality - regardless of shift or site
• 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
  • Higher levels of standardisation and automation

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: Consistently high product quality across all batches - even as product variant complexity increases.
• Reduced manual effort: Significatnly lower susceptibility to errors, faster process execution and noticeable relief for employees in day-to-day production operations.
• Homogeneous system architecture: A stable, future-proof platform that provides a solid foundation for further digitalisation and automation steps-without creating new isolated solutions.
• Transparent and forward-looking production planning: Clear process step information, better preparation for machine operators, fewer downtimes, and optimised handovers.

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.”"