Case Study: Implementing a New MES System for the Food Industry with ArconQ

Intro

Explore how a leading European food company transformed its operations with ArconQ's cutting-edge MES system. From identifying pain points to implementing a customized solution, by reading this case study, you will:

• gain insight into the software development process of one of the leading food processing  companies in Europe
• understand how ArconQ contributed to the whole project from business and technical point of view and what were the advantages of using ArconQ

01 Challenges faced by the food processing industry

The processing industry is suffering from economic burdens caused by high energy and raw material prices, rising wages, and labor shortages. These rising costs make it difficult for companies to offer their products at reasonable prices.

High inflation in recent years, particularly in the food sector, has significantly impacted consumer purchasing behavior and pushed food companies even more. Inefficient processes, lack of real-time data access, and manual record-keeping are some common pain points that hinder productivity and profitability in the food industry.

All that pushed food processing companies even more to search for more optimalisations and software solutions.

1.

Finding a solution with ArconQ

After thorough research and evaluation of various MES systems, the food processing company decided to make fully customizable MES system rather than go for all-fit-one MES system. They turned to reliable partner, that advised to use all-in-one platform: ArconQ for managing and hosting different applications as it has end-to-end integration capabilities, real-time data access, and automated record-keeping.

Moreover, ArconQ's solution was highly customizable, allowing the food company to tailor it according to their specific business needs.

2.

What is MES?

MES, or Manufacturing Execution System, is an advanced control system for managing and monitoring work in progress on a factory floor. The primary function of an MES is to ensure effective execution of the manufacturing operations and improve production output.

By capturing real-time data from the production process, an MES provides valuable insights into every step of the manufacturing process, enabling companies to optimize workflows, improve efficiency, and maintain quality standards.

This system acts as a crucial link between enterprise-level systems, like ERP or SAP, and the operational shop floor activities, ensuring seamless integration and enhanced visibility across the manufacturing lifecycle.

3.

Why MES is Important in Production Companies?

MES plays a vital role in enhancing production efficiency and product quality within manufacturing companies. By providing real-time visibility into production lines, it allows for immediate identification and resolution of bottlenecks or inefficiencies.

This capability leads to improved resource allocation and reduced downtime, ensuring that production schedules are adhered to and customer demands are met promptly. Additionally, MES systems help maintain rigorous quality control by tracking and documenting every aspect of the manufacturing process.

This traceability is critical for compliance with industry standards and regulations. Moreover, MES facilitates better inventory management by accurately forecasting material needs based on current production demand. With its ability to integrate seamlessly with other enterprise systems, an MES ensures that production companies can achieve a high level of operational excellence, enabling them to remain competitive in today's fast-paced market environment.

02 About the client, objectives & challenges

2.1 About the Client

The end customer is a major player in Germany’s food industry, running around 10 large processing facilities. The company handles millions of products each year, supplying both the local and international markets. With growing pressure to be more efficient and sustainable, the client wanted to upgrade their operations, to introduce new quality. Another goal was to use advanced technology to improve productivity, meet high food safety standards, and stay ahead in a very competitive market. This food sector represented by the client is worth approximately €40 billion and contributes around 20% to Germany’s €200 billion food industry.

2.2 Objectives

The main goal was to develop and deploy a robust MES system that integrates seamlessly with existing operations. The project aimed to enhance the client's production efficiency as well and ensure compliance with European Union regulations on cybersecurity and supply chains.

2.3 Challenges

• Developing a complex MES system (for 600 employees working in the factory and 140 workstations) from scratch within a tight three-month deadline.
• Ensuring the system met rigorous compliance standards and integrated well with the client’s existing infrastructure (SAP, PLC, complex IT infrastructure).
• Managing a large-scale project involving numerous stakeholders and departments (the client involved over 50 people from various departments and partners).
• Developed a comprehensive product solution rather than a single software solution – the system should be easily adaptable for use in other project facilities.
• Working with most modern technologies

03 Technology Stack Overview

A well-designed technology stack is essential for driving business success by ensuring that systems are efficient, scalable, and easy to use. These qualities not only streamline operations and reduce costs but also support growth and enhance user satisfaction, making the entire organization more competitive.

At the core of our infrastructure is a Linux-based system that leverages Kubernetes for orchestration, managing services and applications seamlessly. Such solution ensures scalability and reliability across all operations.

The main framework driving our operations is ArconQ, which integrates with the chosen database for this project, PostgreSQL. This framework is pivotal for workflow management, enabling the smooth implementation of production processes on the line.

For logging and search capabilities, we utilize Elasticsearch, primarily during the commissioning phase. This tool aids in tracking material movement and system events, ensuring that all data is easily accessible and searchable.

A crucial part of our system is the Material Tracking framework, which was developed primarily by our developers, Marcin and Piotr. This framework is the heart of our system, handling every event related to item management. Its design allows for reuse in future projects, making it a scalable solution across different applications.

Additionally, we have Lateral Tracking Connectors that manage all external client connections, mostly via TCP. These connectors facilitate data transmission from Level 1 (PLCs) to Level 3 (SAP), ensuring smooth integration between different system levels.

To provide a visual representation for our customers, we use React, which offers a clear and intuitive display of where each item is within the production line. This feature enhances user experience by making complex data more accessible and easier to understand.

04 The Role of ArconQ

“First and the most important, as I said, we would not manage to do this without this cool framework ArconQ. We never got big issues. OK, small things that never blocked us in like, for example, if something was damaged on the production, it  was never a fault of ArconQ”.

Team Leader / Senior Developer
Paweł Urbaniak

“The biggest advantage of ArconQ is, it is simply working. When you introduce a large framework to your project, you never fully know what's inside, and that can lead to critical issues. We didn't have the problems with ArconQ. I don't know how, but that's the true. No, messages were never lost.””.

Team Leader / Senior Developer
Marcin Dyba

“I guess everyone from software engineering knows what it means when you see a testimonial of such a big framework from a project team where they just say hey, it's just snapped in, it just works, you know, and then also you probably said simplicity of communication, fast deployment, so I would say shout out here!”.

IT project manager
Stephan Frank

If I had to highlight one feature in ArconQ that significantly speeds up the implementation it will be communication. In ArconQ you can specify which component receives a message by using a routine ID, and for those familiar with the process, you can even broadcast messages. If a new connection is needed, you simply create a line, and that’s it - implementation is quick and straightforward.

Additionally, the fast deployment and revision control are extremely beneficial. For developers, being able to quickly revert to a previous version when necessary is invaluable. The debugging capabilities are also excellent - you can host the system on your machine while remaining connected to the server applications, receiving real-time messages. This functionality was crucial for efficient development and troubleshooting.

ArconQ supports easy integration with popular third-party tools, enhancing flexibility and functionality. So for example,in this project, we integrated the Elsa framework for a low-code UI-driven approach and the Elastic framework for log monitoring. We plan to use the Graylog framework in future projects.

ArconQ is designed to work with diverse system environments. Its out-of-the-box connectors and standard components allow for rapid application development and integration, whether connecting to sensors, machines, ERP systems, or databases.

05 Implementation & Different Software Development Phases

The project began in 2023, September and was completed in 2023, November with the system going live in 2024.

06 Results & Next steps

The project began in 2023, September and was completed in 2023, November with the system going live in 2024.

• Efficiency: the MES system has been running smoothly since its launch. The first commissioning was completed in January 2024, and the system was up and running with no issues. We weren't even required on-site for it; the applications were simply turned on in the middle of the night.
• No maintenance required: there hasn’t been a single phone call for maintenance.
• After launching the first project, our software was used to commission a second factory. This was accomplished by a single developer, who reused code, resulting in a much faster process than with the first project (faster by 50%).
• The system handles a significant amount of data. There are around 400 messages per second coming into the system and about 600 going out. With 600 employees working in the factory and 140 workstations, the complexity of the system is evident. Each workstation handles tasks such as packing, measuring, and sending items to another station, or managing more complex operations like cutting.

Client Feedback: “The new system has significantly improved our operations and compliance. We are very satisfied with the results. We have already planned new projects in another locations (projects are defined till 2028) and will use ArconQ framework definitely in the future”.

07 Contact Information

The project began in 2023, September and was completed in 2023, November with the system going live in 2024

For more information about this project or to discuss how ArconQ can assist with your automation needs, please contact:

DE: Filip Zuchowski at filip.zuchowski@macrix.eu

EN: Szymon Panfil at szymon.panfil@macrix.eu

08 Final Thought

Looking ahead, adopting a Manufacturing Execution System (MES) for the food industry is no longer merely an option, but a strategic imperative for staying ahead in the competitive market. Our MES solution delivers unparalleled efficiency by streamlining manufacturing processes and ensuring seamless production processes.

The integration of real-time visibility empowers decision-makers to optimize performance at every level, enhancing productivity and ensuring quality. Implementing this system transforms operations, unlocking the potential for innovation and growth.

Trust in our robust framework to pave the path forward for your manufacturing needs. For those ready to elevate their production capabilities, our team is prepared to provide the expertise and technology necessary to succeed.

09 FAQ

1.

What are the key features of the MES system mentioned in the article?

The MES system includes an OPC UA Framework for logging and search, a scalable Material Tracking Framework, Lateral Tracking Connectors for seamless data integration, and MyHost for production line visualization.

2.

How did ArconQ contribute to the development process?

ArconQ simplified the development process with its reliable framework, fast deployment, revision control, and robust debugging capabilities. It is compatible with third-party tools like Elsa and Elastic, enhancing the system's flexibility and functionality.

3.

What were the outcomes of implementing the MES system?

Since its launch, the system has operated smoothly without maintenance calls, commissioned a second factory swiftly by reusing code, and efficiently supports 600 employees across 140 workstations.

4.

What are the future plans for using ArconQ in projects?

Based on the positive results achieved, there are plans to continue using ArconQ for future projects to leverage its strengths for seamless and efficient operations.

5.

Who did this MES implementation?

Macrix Technology Group led the MES implementation process, utilizing its expert team to ensure a seamless integration with existing systems. Macrix's experience and professional approach contributed significantly to the project's success, setting a high standard for future collaborations.