Melitta has been involved for over 100 years in producing and providing services to make life more enjoyable and comfortable. What comes to mind is the Melitta filter paper which goes back to the original idea by Melitta Bentz. In the year 1908, she invented the first filter papers for coffee and thus laid the cornerstone for a very successful family business. Today, Melitta Europe GmbH KG “Enjoy Coffee“ produces filter bags of all types in Minden. Additional locations are in the USA and Brazil, where they produce coffee machines (Melitta), tea filters (Cilia), hoover bags (Swirl) and plastic wraps and bags (Toppits).
Michael Weber, Production Manager at Melitta, Minden
We convinced our staff to accept MES as an important tool of our daily working routine. We would be blind without HYDRA and could not produce that efficiently to survive in a market where we need high productivity and also the cooperation of our staff.
It is essential when manufacturing filter bags to focus on quality, be competitive, environmentally friendly and innovative. Therefore, Melitta uses the holistic MES solution HYDRA by MPDV in their production process. To support the production of filter bags, they work with the modules for Shop Floor and Machine Data Collection as well as Tool and Resource Management. The production orders generated in the leading SAP system are planned via a simple and practical solution for detailed controlling in the MES into the relevant machine or production line.
The data collection terminal signals the next order to the operator and puts in the correct setting of the machine. Also, quantity collection of the machine is directly connected to the terminal. Therefore, HYDRA automatically collects the produced quantity and shows the machine status. If the cycle time has been exceeded, HYDRA identifies a malfunction and asks the operator to select a reason for the malfunction from a predefined list. This enables a standardized evaluation of machine times. The order is logged off at the terminal upon completion. The confirmation of the produced parts to SAP is carried out at the palletizing line.
The collected data in real time enables the system to generate meaningful evaluations which enables the supervisor and Melitta Europa GmbH & Co. KG production manager to have a quick overview regarding the current situation or the previous shifts. A central tool is the Graphical Machinery. At a glance, the supervisor knows, which machines are producing, where the problem areas are and where each order is produced. With introduction of the maintenance schedule for tools, the maintenance intervals now take place after a predetermined number of cycles which is supported by an automatic collection of cycles. This is a great advantage for the production run as targeted maintenance increases machine availability and cost for maintenance is dramatically decreased.
Currently, the introduction of the Energy Management module is being considered to gradually reduce energy consumption. The HYDRA module EMG makes it possible to collect energy consumption and performance values as well as evaluations of data concerning machine and order data. It is then relatively easy to assess, how much energy is used for a certain article. The Energy Management also provides important information to optimize maintenance cycles as increased consumption shows the condition of machines.
- Windows Server with Oracle database
- Interfaces to SAP
- 8 HYDRA Office Clients
- 29 HYDRA Shop Floor Clients
- More than 30 machines connected