SAP Digital Manufacturing Enhances aquatherm’s Operations

SAP Digital Manufacturing has become a pivotal tool in optimizing production processes, especially for companies like aquatherm that aim to increase efficiency while contributing to sustainable practices.

aquatherm, a prominent German manufacturer, specializes in plastic piping systems made from polypropylene, a material known for its environmental benefits and resilience under high temperatures and pressures. With a product line comprising 17,000 items, aquatherm caters to a range of applications, including heating, cooling, and potable water systems. Operating in 70 countries with a workforce of around 500 employees, aquatherm is committed to environmental stewardship, providing sustainable products and services that align with global climate protection goals.

In response to growing demands and the need to streamline its production, aquatherm sought a solution that would reduce manual data entry, enhance data accuracy, and mitigate human error. Although the company had implemented SAP S/4HANA Cloud as its core business system in 2022, it remained heavily reliant on manual processes, which posed risks to data quality and operational efficiency.

To address these challenges, aquatherm integrated SAP Digital Manufacturing, a Manufacturing Execution System (MES) that facilitates efficient manufacturing operations through real-time data and analytics. This system enables companies to connect corporate systems with shop floor equipment, optimizing production by integrating execution, visibility, and analytics. The solution is cloud-based, providing real-time insights into production processes, machine performance, and potential issues, thereby allowing for more informed decision-making.

Optimizing Production with SAP Digital Manufacturing

The implementation of the SAP solution began in one of aquatherm’s production areas, where it provided critical insights into machine performance and production bottlenecks. By connecting SAP S/4HANA Cloud with SAP Digital Manufacturing, aquatherm established a central data source, ensuring seamless data exchange and real-time updates. This integration has significantly reduced downtime and enhanced the overall efficiency of the production process. (InsideSAP often references articles from websites in other languages to bring you as much information as possible.) 

Patrick Keller, SAP Technical Consultant at aquatherm, emphasized the importance of automating production processes across multiple departments and lines. The goal was to minimize manual inputs, streamline operations, and achieve comprehensive traceability throughout the production cycle. Keller noted that the adoption of SAP Digital Manufacturing allowed aquatherm to establish a more transparent and data-driven production environment, with automatic data exchange cutting down PC-based tasks by 90%. This reduction in manual processes has improved data quality and freed up valuable time for machine operators.

One of the main challenges during implementation was sourcing accurate machine data from various manufacturers, each with different standards. To overcome this, aquatherm, in collaboration with SAP and its partner BA Business Advice GmbH, developed standardized templates for each machine. By adhering to SAP’s fit-to-standard implementation approach, aquatherm avoided extensive custom developments, ensuring that existing production processes remained largely unchanged. This strategy enabled the company to complete the implementation within six months, following a three-month proof of concept.

Looking ahead, aquatherm plans to expand the use of SAP Digital Manufacturing across all its production areas. The company also intends to leverage the SAP Digital Manufacturing Cloud for Analytics to further enhance production control and data exchange between SAP S/4HANA Cloud and SAP Digital Manufacturing. Additionally, aquatherm plans to integrate SAP Analytics Cloud and the Production Connector to facilitate data exchange between SAP Digital Manufacturing and industry-specific data sources.

Keller highlighted that the centralization and automation achieved through SAP Digital Manufacturing have eliminated blind spots in aquatherm’s operations. Accurate, real-time data now supports smooth and efficient production processes, laying the groundwork for future advancements in data analytics and AI solutions to further optimize production efficiency.

Through the adoption of SAP Digital Manufacturing, aquatherm has made significant strides in digitizing its production processes, reducing manual workloads, and improving overall operational transparency. As the company continues to expand its use of SAP solutions, it remains committed to enhancing efficiency and sustainability in its operations.