Industry 4.0 Archive - dmaic software GmbH & Co. KG

Guidance for MES Implementation

Alexa Buddensiek — Thu, 25 Jun 2026 07:55:39 +0000

New Practical Guide: A Structured Approach to MES Integration in Furniture Manufacturing

As markets become increasingly uncertain, production processes need to become more reliable. For many furniture manufacturers, MES implementation in discrete manufacturing is therefore becoming a key lever for measurably improving planning, material flow and transparency in day-to-day production.

When evaluating MES solutions, one thing quickly becomes clear: the market is diverse and the described functions often appear similar. In practical use, however, differences emerge that are decisive for the long-term value of the system.

Selecting an MES is therefore not a short-term decision. It requires a well-founded assessment. At the same time, day-to-day operations often leave little room to examine every relevant question in depth. This practical guide brings together insights from 14 years of MES projects, outlines proven implementation approaches and includes real use cases from the daily operations of our partners.

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How criteria-based sequence optimization measurably reduces lead times

Alexa Buddensiek — Fri, 27 Feb 2026 14:25:24 +0000

In many manufacturing companies, the primary goal is to shorten lead times, utilize machine capacities optimally and increase overall production performance. Both mass manufacturers and, in particular, batch-size-one operations with highly variant product portfolios and frequent changeovers are confronted with this challenge. There are numerous levers that can influence throughput time, machine utilization or overall output. In production, a wide range of factors affect productivity – from machine occupancy and material availability to set-up times and order prioritization. Managing these interdependencies manually is hardly feasible and often results in time‑consuming coordination efforts and trial‑and‑error planning.

Cost-efficient optimization in detailed planning

For optimal alignment in detailed planning, dsProSequence is available as a solution that has been developed as an integrated component of the MES system. The module automatically determines the most efficient processing sequence for cutting plans, components or finished products and takes all relevant production factors into account, which can be configured individually. Planners can, for example, define whether the system should focus more on short lead times, minimal changeovers or balanced machine utilization. As a result, planning control always remains in the hands of production management, while the tool reliably handles the underlying complexity.

Automated control of key criteria

dsProSequence enables planners to weight lead times, set-up times and machine utilization simultaneously. On this basis, a balanced production sequence is generated that

reduces lead times
improves machine utilization
avoids bottlenecks
increases overall production performance
and minimizes planning effort.

Productivity gains with measurable benefits

Tests in real production environments show that the use of dsProSequence can significantly reduce total production time. Depending on the production structure and the variety of product variants, lead times can be reduced by measurable percentage values and bottlenecks can be significantly decreased.

The results demonstrate that data-driven sequence optimization not only reduces planning effort, but also clearly improves overall production performance – a key step towards more efficient, stable and future-proof manufacturing.

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Efficiency gains through centralized inventory management

Alexa Buddensiek — Fri, 06 Feb 2026 10:29:23 +0000

In furniture manufacturing, production processes are becoming increasingly variant-rich – and with them, the effort required for inventory counts rises dramatically. For many production managers, this means double the stress: personnel capacities that need to be allocated, potentially longer production stops and additional time losses due to data transfer to the ERP. Compounded by dissatisfied employees, as inventory management is unnecessarily complicated by multiple parallel systems that do not communicate with each other.

Streamlined inventory via MES integration

Inventory processes can be seamlessly controlled via the MES. Through interfaces, data is not only collected and consolidated at a central location, but also transferred directly to the ERP, where it is visible to the people working with it. With the mobile Android app, inventory counts in the warehouse become significantly easier, noticeably shorter, and require no manual follow-up work. This provides a central platform with reliable count data, which is then transferred to all connected systems.

Time and Cost Savings: Avoidance of production downtime or weekend work, reduced personnel deployment, fewer downtimes.
Simple Capture: The mobile app replaces manual recording on paper or Excel lists and books via scan in real time on site.
Reliable Data: Automatic system consolidation, direct ERP integration.
Higher Satisfaction: Smoother processes.

Switching inventory processes to dmaic MES ensures a stress-free and precise inventory despite variant diversity and gives production managers back control.

Key numbers from practice

Our customer Febrü has shifted its inventory processes to the MES, thereby securing measurable benefits and audit-proof processes.

In practice, Febrü achieved key successes through the switch to MES:

Up to 50% reduction in personnel deployment in the inventory process
Significant relief for employees
Around 70% less manual counting effort through digital capture
Complete elimination of manual ERP follow-up work through automatic data transfer

Inventory thus becomes plannable, scalable and easier.

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Structuring mobile buffer storage – reducing search time and increasing transparency

Alexa Buddensiek — Fri, 06 Feb 2026 10:05:48 +0000

How Structured Buffer Storage Stabilizes Processes

Buffer storage such as transport carts or rack trolleys are more than just mobile storage surfaces. What many production managers lack is a suitable tool to digitally structure these interim storage areas in order to reduce search time, eliminate confusion, and prevent unnecessary interruptions in process steps.

Creating Transparency

Transport carts can be organized like a real buffer warehouse. Each cart is uniquely identified via code. Components are digitally recorded and assigned to the respective cart by scanning. Likewise, parts can be easily transferred from a cart to the designated warehouse or production area through a simple scan.

Each cart is uniquely identifiable (via barcode, QR code or RFID tag)
Each level is logically mapped (with preview on the workstation screen)
Every part is clearly assigned to a storage location (cart + level)
Paper or Excel lists are replaced by digital views that update in real time

This makes it possible at any time to track which component is located on which cart and at which level. The result: reduced search times and full transparency.

Digital Control Instead of Manual Distribution

The allocation of materials to transport carts becomes a fully digitally controlled process that can be managed manually, semi-automatically, or fully automatically.

Manual: Employees retain full control over the assignment process, while benefiting from complete digital transparency regarding the status, contents, and destination of each cart.

Semi-automated: Orders are specifically selected, and the system takes over the intelligent allocation to suitable transport carts based on defined production logic.

Fully automated: After importing order data, assignment takes place automatically without manual intervention. This relieves employees and creates capacity for value-adding activities.

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Efficiency meets sustainability: packaging optimization as the way forward

info@dmaic-software.de — Mon, 03 Jul 2023 07:36:56 +0000

The subject of packaging waste has received significant social and political focus in the last few years. Due to the growing awareness of sustainability, the issue of packaging waste has become one of the most important challenges for companies.

In Germany, the scale of the problem is particularly dramatic: with 19 million tons of packaging used annually, the urgent need for an efficient and effective solution is becoming increasingly clear. This is not just an ecological and moral issue. Consumers themselves are becoming more and more concerned and alarmed by the flood of packaging waste. According to a study, 45% of consumers feel significantly disturbed by packaging waste and more than a quarter of respondents even stop buying products that, in their opinion, generate too much packaging waste.

There is a clear consensus here: consumers see manufacturers as having a duty to reduce this waste. Almost half of all consumers, 45%, consider the producers of the goods to be primarily responsible for reducing packaging waste.

However, it is not just a question of environmental protection. The economic demands and pressures are also increasing. From 2020 to 2022, the producer price index for wood packaging has almost doubled. Prices for other packaging materials, such as corrugated board or plastic, have also increased significantly. These rising costs for packaging materials are forcing manufacturers to put current operations and processes to the test and. It is obvious that changes need to be made to current practices and strategies and that comprehensive optimization of processes is necessary.

Development of producer price index of packaging (DE)

Packaging optimization: an effective way to shape the future

In view of the growing challenges around packaging waste, packaging optimization from dmaic offers an efficient and effective solution. Our approach combines reduction of material consumption and efficient use of resources. By using modern technologies such as automation and 3D calculation, we maximize packaging utilization and minimize waste.

The advantages are many: costs for packaging and logistics are reduced, unnecessary waste is avoided, and transport damage is reduced through careful planning and appropriate surface treatment. Thanks to our approach of looking at each packaging process individually, we are flexible and can adapt to changing part combinations and lot sizes.

You can find more information about our diverse solutions here.

Sources: Genesis online database – 61241-0003 Federal Environmental Agency Statista survey on disposal behavior

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