SAP knows what should be produced. The floor knows what was produced. We connect the two through SAP PCo and OPC UA, all the way down to the controllers, and measure OEE from the machine.
We talk to the PLCs through SAP Plant Connectivity and OPC UA. Counts, states and alarms arrive in the MES as they happen, and SAP receives confirmations while the shift is still running.
Every stop is timed by the controller and given a reason by the operator. Downtime stops being a memory exercise at the end of the shift.
Actual cycle time against the standard, per machine and per order, so slow running is seen as it happens.
Good and scrap counts from the line, matched to the batch, so first-pass yield is a number and not an opinion.
Losses are ranked by machine, shift, product and reason. Improvement work starts from the biggest loss, with data the whole plant trusts.
Five layers, data moving in both directions. Instructions go down. Production telemetry comes up in real time.
SAP knows what should be produced. The shop floor knows what was produced. We close the gap between them with execution systems and shop-floor applications that report confirmations, material consumption, batches and serial numbers as the work happens.
Because the counts come from the controllers, OEE stops being a monthly spreadsheet. Availability, performance and quality are calculated per machine, shift and order, every stop has a reason code, and process improvement starts from data the whole plant trusts.
Reporting follows the way each line works: time ticket confirmations for labor and machine time, time events for start, interruption and finish, quantity-based reporting for batch production and serial-by-serial reporting where every unit matters. Production and quality run as one process: in-process inspection lots open from the confirmation, lab results and data collection flow back to the order, and the batch is released with its results attached.
Futera connects enterprise software to the machines that do the work. We talk to PLCs and production equipment through SAP Plant Connectivity (PCo) and OPC UA, read cycles, states, counts and alarms straight from the controllers, bring them into MES and SAP, and send production instructions back the other way.
The planner sees what the machine actually did. The machine receives what the plan actually needs.
Quality work is document work: certificates of analysis, inspection results, non-conformance reports. We implement the SAP QM processes behind them and use document extraction to read incoming certificates and check them against the specification automatically.
When something goes wrong, the process has to be just as clear: a defect is recorded where it is found, the material is blocked, the review board decides on rework, use-as-is, scrap or return to vendor, and the corrective action is followed to closure. We build that as one flow on SAP quality notifications, not as a folder of forms.
Production orders travel from SAP to the line. Cycles, states and stops travel back from the controllers through SAP Plant Connectivity (PCo) and OPC UA. OEE is measured from the machine, not estimated from paper.
Supplier certificates of analysis are read by AI, the measured values are matched to the SAP inspection lot, and quality staff follow every document from arrival to recorded results in one web screen.
A web wizard that walks a new material through every department and every stakeholder, step by step, and creates the complete material in SAP, with all its views and extensions, in one step at the end.
Describe what is slow, manual or on paper in two lines. No deck, no sales pitch: you get a reply from an engineer with how we would approach it.
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