For smart factories to become a reality, machines and systems in all subdomains must communicate with each other and must be digitized end-to-end. The Durr Group uses its manufacturing and digital technologies to combine hardware and software. On this basis, Durr software experts and Durr’s iTAC company jointly developed a modular solution for production planning, execution, control, monitoring, optimization and predictive analytics. The new Manufacturing Operations Management (MOM) system is not a monolithic stand-alone solution, but is comprised of microservices that provide the required functionality, achieve a high degree of flexibility and consistency, and provide multiple interoperable interfaces. The two companies will present the system at Hannover MESse, Germany, from 17 to 21 April 2023, where they will jointly exhibit the system in Hall 15, Booth E34.

Each digital factory has three central advanced control components: a Manufacturing Execution system (MES) to control and monitor production, a supervisory control and Data acquisition system (SCADA) to collect and analyze data, and a human-computer interaction interface (HMI) to visualize production and processes. Until now, the three major control components (e.g., manufacturing execution system components) have mostly been designed independently. Durr and iTAC combine the strengths of Durr’s DXQcontrol product family and iTAC’s ITac.MOM.Suite to design smart factory functions into several interoperable modules, thus integrating the functions of the three components into a unified manufacturing operations management (MOM) architecture. A future-proof industrial digitization solution for ownership shaping enterprises, whether manufacturers or suppliers.

Microservices architecture for Agile manufacturing

Unlike traditional manufacturing execution systems (MES) systems, where a single piece of software contains different functions (such as data acquisition or logistics), the new Manufacturing Operations management (MOM) system developed by Durr and iTAC uses a modular architecture in which multiple micro-operations interact and communicate while performing their respective tasks independently. Unlike monolithic systems, microservices have independent data storage and are equipped with open interfaces to communicate with other microservices for flexible deployment. With the new Manufacturing Operations Management (MOM) system, only the necessary modules are installed, so fewer servers are required and operations are more sustainable. At the same time, due to the modular structure, the system has a lower error rate, thus improving plant availability.

Variable availability: cloud, offline, or hybrid

Microservices have another advantage: they can be flexibly installed on IIoT platforms in the cloud, in the field (production facilities) or in hybrid factories. For example, if a customer is concerned about operational costs or production stability, they can use a specific cloud service while also using other features offline. Hybrid solutions are particularly advantageous when it comes to handling large amounts of data at the terabyte level. If some data is processed locally (“on-edge”, i.e. in a local environment), not all data sets must be transferred to the cloud/iot platform through multiple exchanges, thus saving time, cost and energy. In addition, local data processing is extremely fast, making it possible to control the manufacturing process in real time.

Sustainable production management

In addition to the new Manufacturing Operations Management (MOM) system, Durr and its subsidiaries iTAC Software AG and Dualis GmbH IT Solution will be showcased at the Hannover MESse in Germany, along with other new products that are in line with industry trends. Among them, sustainable and energy-efficient production management is another focus of the expo. For example, Durr will demonstrate its ISO 50001-certified DXQenergy.management software, which maps media consumption across a production line and systematically detects consumption anomalies to identify potential energy savings. Dualis’ GANTTPLAN planning tool monitors energy costs incurred during production planning.

Manufacturing data analytics and intelligence

Both Durr and iTAC are launching data analytics tools that leverage artificial intelligence to improve production quality and availability as part of a manufacturing Operations management (MOM) system. These tools can evaluate production and quality data, detect potential defects or impending wear, and use machine learning to make predictions. In addition, the integration of preventive and predictive services and edge technologies enables performance optimization, added value, and data sovereignty.