Machine integration with SAP Business One via GRAIDWARE®
Viktor WagnerPublicationUpdate
Everything you need to know about connecting machines to SAP Business One using GRAIDWARE® at a glance
- The GRAIDWARE® middleware acts as an intelligent link between the ERP level and production.
- Production orders and product master data flow directly from SAP Business One into the process without the need for manual input.
- The technical connection is established via an OPC UA standard, thereby preserving the machine manufacturer’s warranty.
- The system is capable of automatically stopping the plant if the wrong material is used, thus preventing costly scrap.
- Information on material consumption and quantities is reported back to SAP Business One in real time.
- The specialist sister companies of the SIGMA Group implement this holistic integration as a complete solution.
Why is middleware such as GRAIDWARE® essential for production?
Modern manufacturing facilities continuously generate vast amounts of data, which are crucial for quality assurance and traceability. Without suitable middleware, this data would have to be transferred manually or connected to SAP Business One via rigid individual interfaces as part of a machine connection.
GRAIDWARE® acts as a translator: it receives the specifications from the production order and distributes them in real time to the relevant stations. This significantly reduces the complexity of the IT infrastructure, as there is no need to build individual database solutions for each machine.
How is the technical integration carried out without interfering with the machine control system?
A critical aspect of machine integration is the stability of the plant control system. GRAIDWARE® utilises the OPC UA (Open Platform Communications Unified Architecture) standard for this purpose. Process parameters are read via an OPC UA server without the need to make any changes to the machine’s actual programming. As communication takes place at the protocol level, the machine manufacturer’s warranty remains unaffected. GRAIDWARE® acts as a software layer that exchanges data in both directions. Thanks to this bidirectional data exchange, machine statuses are retrieved in real time and relevant production specifications are transmitted directly to the respective stations.
„Our aim is to completely break down the barriers between the shop floor and the ERP system. With GRAIDWARE®, we create a digital bridge that not only transfers data but also makes it usable for SAP Business One, without compromising the sensitive processes of machine control.“
-Viktor Wagner, Managing Director SIGMA Enterprise Solutions GmbH
How GRAIDWARE® works
The middleware acts as a central data hub and controls the distribution of all production-related information in real time to the relevant production stations. This involves the automatic transfer of product master data, cycle times and bills of materials from SAP Business One, eliminating the need for manual input. GRAIDWARE® ensures maximum transparency at both automated machines and manual workstations. Employees receive precise, variance-specific instructions and material lists directly via their terminal, thereby minimising errors and speeding up processes.
What are the advantages of storing parameters on a component-by-component basis?
Whilst many systems store data only at item or batch level, GRAIDWARE® enables part-specific storage. This means that the exact process parameters are archived for every single item produced, each with its own serial number. Combined with the automated feed-back of material consumption and quantities to SAP Business One, this creates a complete digital history for every product.
How do SIGMA’s sister companies achieve this integration?
Successfully connecting machinery and integrating production with the business level requires in-depth expertise in two distinct areas. Within the SIGMA Group, this is made possible through close collaboration between two sister companies: SIGMA Software und Consulting GmbH handles the strategic integration into SAP Business One. It ensures that production orders, material flows and confirmations fit seamlessly into your company’s business logic. In parallel, SIGMA Enterprise Solutions GmbH is responsible for the technological implementation of the GRAIDWARE® middleware. It handles the physical connection of the machines and the integration of auto-ID systems such as RFID, barcodes, QR codes, Data Matrix codes and much more. Thanks to this combined expertise, customers receive a comprehensive solution from a single source.
The integration provides full real-time transparency, as production data and machine status are fed directly into SAP Business One. Automated data exchange eliminates the need for manual data entry, which significantly reduces the error rate. As the system can also monitor threshold values, businesses benefit from predictive maintenance and higher equipment availability.
The middleware uses encrypted standards for bidirectional data exchange. Another key security factor is that, in the vast majority of cases, GRAIDWARE® is run directly on a server within the customer’s secure production network. Furthermore, the automatic import of product master data and bills of materials eliminates the risk of human error.
Yes, the integration of GRAIDWARE® is designed to make optimal use of existing structures such as production orders and stock transactions in SAP Business One. In addition, the software features a comprehensive order management module that can map the workflows and data structures required for shop floor processes.
Viktor Wagner
Managing Director
Viktor Wagner has 12 years of professional experience as a consultant for digitalization at SIGMA Chemnitz. His expertise covers various areas, including RFID applications and the planning of RFID projects, the assessment of the feasibility of RFID projects, the design of solutions and the sale of software solutions.
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