Challenge: Making production transparent

Bayer AG is a global life science company with a focus on healthcare and agriculture. Modern production and digitalization approaches have been implemented at the Bayer Bitterfeld site, one of the Group's most digital plants, since it was founded in 1991.

The Bitterfeld plant already had a high level of digitalization - but with many different individual solutions. Each department used its own tools or self-programmed applications to close data gaps.

To reconcile the information, the departments first had to prepare their data separately and bring it together in several daily meetings. These meetings took around two hours a day and delayed decisions because relevant information had to be painstakingly collected from different systems.

Bayer Bitterfeld became aware of the OPC router through a recommendation from another plant. After a test phase on a separate system, the team gradually integrated the OPC router into the existing landscape. Those responsible were able to configure many connections themselves; the OPC router tutorials helped with any questions.

Today, several OPC routers are in productive use and act as a data hub between the departments. The previously existing individual solutions have been completely replaced. Machine data is collected by Kepware's KEPServerEX via OPC UA, stored in a MongoDB for long-term use and, if necessary, reported to the responsible employees by email notification - for example in the event of production downtime or deviating values.

The OPC router also provides all relevant information directly to the machine: production statuses, open orders and the current status of the system are visible at all times. Each department was able to create its own visualizations on this basis and can see the key figures that are important to them at a glance.