Like many manufacturing companies, Pivovarna Laško Union faces several production-related challenges, such as reducing costs, increasing equipment utilization and optimizing key production indicators. To improve overall efficiency, manage production line operations and optimize production capacities, identifying bottlenecks is essential, requiring detailed analysis of delays and their root causes. Additionally, production management needs tools to monitor and control the process in terms of efficiency, planned and unplanned downtime, regular operations, cleaning, line changes, inspections and other processes.

MePIS bridges the information gap between business (ERP) and process (PLC, SCADA) systems by automatically capturing data on production line performance, while also extracting business information from the ERP system. MePIS OPEX, a key component, facilitates the analysis of downtime events and production line efficiency by enabling automatic detection and classification of delays based on configured rules, with integration into production devices.

Along with downtime data, MePIS captures production volume data to calculate and display various KPIs, which are presented via a user-friendly web interface. These calculations are performed continuously in real time. Detailed analysis and comparisons are possible using OLAP-collected data, which is integrated into MePIS OPEX. Users can access the data both online and via mobile devices, enabling management to respond quickly when unexpected production events occur.

The implementation of MePIS has significantly improved digitalization across key segments of Pivovarna Laško Union’s production processes, leading to several key improvements.

Real-time monitoring of production lines lays the foundation for introducing standard efficiency metrics such as Overall Equipment Effectiveness (OEE). With precise logging and classification of downtime, congestion points become visible in real time, allowing for immediate action. Analytical reporting tools enable comparative analysis across plants, production lines and products, fostering continuous improvements.

With its strategy of continuous innovation and improvement, Danfoss recognized the need to optimize production processes and improve product quality to boost competitiveness. To achieve these goals, Danfoss chose to implement MePIS MES and MePIS OPEX, which provide control over production processes, automatic monitoring of quality parameters and optimized micro-planning of production. Danfoss sought to implement these solutions in its plants located in Slovenia, Denmark, Poland and China, allowing for comparison of key performance indicators (KPIs) between locations and the transfer of best practices.

Given the global distribution of production sites, it was also important to be able to introduce and expand a unified solution gradually across different countries, while operating in local languages.

To enhance production efficiency, Danfoss introduced the MePIS MES and MePIS OPEX, solutions, which are fully integrated and function as a single system for the user. These solutions are also linked to other production IT systems (e.g., ERP, WMS), enabling automatic real-time data exchange.

MePIS MES provides a wide range of functionalities essential for managing production processes, from electronic work orders and micro-planning of operator tasks to internal supply chain management, waste management and SPC (Statistical Process Control) with automatic data acquisition. Real-time data is also shared with other IT systems, allowing for the generation of various reports and analyses.

MePIS OPEX offers extensive analytical capabilities to improve productivity and efficiency in production processes. It detects downtime using automated measurements from production machines and includes a mechanism to calculate a large range of KPIs, which can be presented in customized reports. It also connects line operators with other personnel and can facilitate information sharing on production events (e.g., maintenance or quality issues).

Both solutions offer a top-tier user experience with customizable interfaces and operation in multiple languages, including English, Slovenian, Chinese, Danish and Polish.

By automatically collecting data from production machines and with additional manual inputs, MePIS MES and MePIS OPEX provide Danfoss with a comprehensive overview of production processes. These solutions serve as the foundation for detailed insights into operations and the development of improvement initiatives, such as reducing production cycle times. In addition to improving internal supply chains, maintenance and quality parameters, they allow for the quick and efficient identification and elimination of losses and downtime.

Managers can gain an in-depth view of production performance at any time and compare it across different plants without additional burden. MePIS solutions also enable real-time two-way data exchange between Danfoss’s ERP system and production processes.

Based on the collected KPIs, Danfoss can implement measures to increase productivity and achieve immediate savings. Metronik’s solutions are tailored to Danfoss’s internal processes and best practices to support continuous improvement.

Our collaboration with Cinkarna Celje began in 2010 when we were selected to implement a Production Information System (PIS) for its titanium dioxide production plant, the company’s main product, which generates over 80% of its annual revenue.

Over time, the system became technologically outdated, and the need for additional functionalities arose. Cinkarna Celje therefore decided to overhaul the system completely and entrusted Metronik with the execution of this complex development project.

The key expected outcomes of the SPEKTER 2.0 system are the further reduction of production costs, improved product quality and enhanced operational safety.

To implement SPEKTER 2.0 we used our own development platform, which is based on the latest technologies and enables the rapid and efficient development of a secure and scalable IT solution.

The main functionalities include the centralization and review of data from various production systems, which are then used to calculate global indicators (KPIs) for managing quality, production efficiency and achieving planned production targets.

For production monitoring, block diagrams offer a quick overview of operations within the selected process, and more than 30 synoptics visualize the status of equipment and processes.

Automated alerts, notifications and the logging and analysis of downtime and bottlenecks, as well as traceability of both the primary and secondary production chains, significantly reduce the need for repeated manual checks across different areas.

The solution also includes energy management tools (data review, trend analysis – M&T, consumption forecasting) and environmental management (monitoring and reporting on environmental parameters, reports for ARSO).

Another important feature is the automatic generation of over 100 reports.

Additionally, two new packages are planned: one for displaying groundwater level probe data and another for integrating batch data.

With the renewed information system, Cinkarna Celje’s users now have efficient and reliable access to real-time production parameters. This contributes to cost optimization, improved product quality and provides a valuable tool for work process planning and internal and external reporting. The system can be accessed from anywhere and on multiple devices, offering flexibility and convenience to its users.

Over the last five years, production at Incom has doubled, and in the past decade, it has grown sixfold. This rapid expansion has led to some typical challenges, such as decreased production visibility, more frequent human errors and less efficient utilization of production capacity.

To overcome these issues, Incom opted for digital transformation, choosing Metronik as their partner to help increase productivity and optimize production processes.

The primary objective was to implement the MePIS MES system to track production quantities, record work hours, manage product labeling, ensure the correct material is issued to the production lines and provide efficient access to production documentation.

The MePIS OPEX solution was introduced to improve production visibility. By processing and displaying data from production equipment and the ERP system, we gave key stakeholders a real-time view of production, enabling rapid response in case of deviations. Workers also receive continuous feedback on their performance through motivational screens. Management can analyze historical data to develop improvement measures and actively monitor their effectiveness.

The automatic collection of data from production machines, combined with manual inputs, forms the foundation for the comprehensive visibility of production processes that MePIS MES and MePIS OPEX provide. These systems enable improvements like reducing production cycles, optimizing internal supply chains and enhancing maintenance and quality control parameters.

Bottlenecks in production can be quickly and efficiently identified and addressed. MePIS MES simplifies the input of quantities through a web application and portable terminals, streamlines label preparation and ensures easy access to essential documentation. Management can access a detailed view of production performance at any time without extra effort.

MePIS also allows for real-time, two-way data exchange with ERP systems. Using the gathered KPIs, Incom can introduce productivity improvements and achieve immediate cost savings.

Metronik’s solutions, tailored to internal processes and best practices, serve as the foundation for building a smart factory.

As a contract manufacturer for other pharmaceutical companies, Marifarm faces two key challenges. First, it must ensure high-quality production in regulatory compliance, essential for partnering with reputable companies in the broader region. Second, it must maintain cost control, production efficiency and high productivity to remain profitable. The digitalization of production effectively addresses both challenges, a fact recognized by the company’s ambitious management, which fully supports the systematic modernization of its processes. In partnership with Metronik, Marifarm has implemented several modules from the MePIS family, including the MePIS LS MES system for the pharmaceutical industry.

Marifarm’s comprehensive digital transformation is built on four main solution pillars:

With the introduction of MePIS LS Marifarm has fully digitized its production. By eliminating paper-based operations in packaging, operators are now able to focus more on the production process, which is managed through the application. Data is recorded continuously, and the traceability of material flow is improved through optical recognition, reducing errors and non-compliance issues. Electronic reports are now readily available, along with other significant benefits.

MePIS OPEX provides a detailed view of the efficiency of packaging lines, identifying parts of the process that cause losses and enabling the development of measures to improve performance.

MePIS RM ensures that only approved settings are used on machines, which cannot be altered by operators. Process parameter data from work orders is transferred to MePIS PDM, where it can be analyzed and compared using graphical and tabular displays, allowing for the preparation of GMP-compliant reports.

With MePIS Energy Marifarm can systematically monitor energy consumption and improve the energy efficiency of production processes, lowering associated costs and reducing its carbon footprint.

Additionally, some production data is transferred to the ERP system for financial and material management, eliminating the need for manual data entry.

The HVAC and energy automation solution complies with GMP requirements. The control algorithms for energy systems are designed to ensure high energy efficiency in addition to meeting the required conditions. The quality and reliability of the system are demonstrated by its uninterrupted operation since 2008.

For a high-end hotel facility, it is crucial to ensure seamless integration between room automation and energy management into a unified Central Control System (CCS) to guarantee operational efficiency and guest comfort. The tight timeline for implementing these solutions posed an additional challenge.

Hotel room automation was implemented using a VDA system, which manages heating, cooling via fan convectors, underfloor heating and lighting, all adjusted based on the guest’s presence in the room.

The VDA system is linked to an Assa Abloy access control system, which provides data on door status to trigger welcome lighting and signal “do not disturb” and “clean room” statuses upon room entry.

Automation of the heating and cooling in common areas, the central boiler room for hot and cold water, DALI smart lighting and management of different group settings in the reception, restaurant and conference rooms were all handled via Honeywell controllers.

The Honeywell Arena NX central control system was deployed to manage all energy systems (heating, cooling and ventilation) across both common areas and hotel rooms.

The 123-room hotel has achieved a high level of automation in room management, HVAC and CCS.

Key benefits for guests include a premium user experience with intuitive control of in-room devices and enhanced comfort.

For hotel management, full control over energy systems and consumption, both in rooms and throughout the entire property, ensures efficient operation of the facility.

The new plant in Turda required a modern MES to provide a digital framework for production management and achieve several key goals: paperless production, reduced manual work for operators, support for QM and regulatory compliance, a transparent view of the manufacturing process, optimized productivity and adherence to strict/short implementation deadlines. Both new and standard Stada production processes were implemented to meet these demands.

In the packaging department at Stada, a comprehensive MePIS LS MES solution was implemented, encompassing material flow control, MBR/EBR, equipment management, exception management and generic MBRs. A full validation package was included to ensure compliance with GMP and 21 CFR Part 11 regulations. The system was also integrated with the company’s ERP system (SAP) and the shop floor. Additionally, a digital showroom was set up to display room status in real-time, further enhancing operational transparency and efficiency.

Stada saw improvements in GMP and regulatory compliance, with customized production report approval workflows enhancing data integrity. Paper documentation and manual work in data management were significantly reduced. Visualization and comparison of process parameters became easier, leading to optimal settings for production processes. Batch comparisons and analyses (golden batch) were also facilitated. Moreover, data exports for reporting and analytics became quicker, and responses to problems and critical alarms were much faster thanks to a real-time system status overview.

Good Manufacturing Practices GMP (Good Manufacturing Practice) are a set of guidelines and standards that pharmaceutical companies must follow to ensure the quality, safety and efficacy of their medicines and pharmaceutical products. Ensuring GMP compliance is one of the key factors in the pharmaceutical industry, presenting several typical challenges.

Chief among these are the efficient transfer of formulations to production equipment, the collection, management and secure storage of process and reporting data, including integration with the Manufacturing Execution System (MES). Equally important is the rapid analysis of data and comparison with preset limits.

After evaluating international providers, Novartis selected Metronik’s MePIS RM and MePIS PDM, solutions, which are tailored to the specific needs of pharmaceutical manufacturing for managing and digitizing the lifecycle of production recipes and reports.

Metronik’s MePIS RM is designed for central management, storage and automated transfer of production recipes for setting up production facilities. It allows users to manage the recipe lifecycle digitally, following a workflow that can be independently configured. It ensures that only recipes with all required approvals are available for production. The automated transfer of approved recipes to machines is handled by MePIS RM, or triggered from the MES system.

The MePIS PDM solution provides a validated central repository for data, events and alarms from the production process, along with the ability to generate production reports and conduct in-depth data analysis. Data in the central repository, organized according to the production model, serves as the source for reports and all further processing.

In addition to basic data viewing, the solution enables batch-to-batch comparisons, measurement comparisons with alarms in a unified view and an overview of the most frequent alarms on specific equipment or throughout the entire plant. It also supports periodic or automatic reporting of production data to the MES when anomalies are detected.

A key feature of the solution is the digital management of report lifecycles, which ensures that the system manages the status of each report and user rights concerning the reports.

With the implementation of Metronik’s MePIS RM and MePIS PDM solutions, Novartis has achieved several key improvements. Automated data collection and storage have enabled paperless operations, reducing the need for manual data entry and decreasing the frequency of errors. Comprehensive data integrity helps improve compliance with regulatory requirements, while enhanced visibility of production data allows for faster response to anomalies and the identification of opportunities to optimize production processes.

The quality and efficiency of Metronik’s solutions have also led Novartis to adopt Metronik as a technology partner for digitalizing its manufacturing operations on an international scale.

The project involved strict adherence to internal norms and BREEAM certification, utilizing advanced technologies not commonly found in the region. These include concrete core activation, passive cooling with groundwater, heating and cooling via thermal shafts and air quality regulation in individual rooms, methods mainly typical of Scandinavian countries.

A high level of system integration is required for sustainable and efficient building operation, managed by a Central Control System (CCS). This system oversees:

The technologically advanced solutions, including the Central Control System (CCS), allow the energy-demanding and environmentally sensitive IKEA Ljubljana store to operate efficiently and sustainably, in line with rigorous sustainability principles and standards.

Chemical laboratories in FKKT use hazardous media and chemicals that require careful management to prevent harmful leaks. Automation systems must maintain negative pressure to control leaks and ensure safety. If anomalies occur, the system must act swiftly to secure the space, and it should also prevent the flow of natural gas in poorly ventilated areas or increase ventilation if needed.

These challenges necessitated a complex Central Control System (CCS) for energy systems and devices, which was implemented by Metronik.

Metronik’s CCS integrates and manages all systems related to energy consumption, including boilers, cooling, heating, air conditioning, lighting and shading. Flexibility and energy efficiency are ensured by using proven controllers for heating/cooling and other key systems.

Glede na zahtevnost in namen posameznih energetskih sistemov smo pri izvedbi projekta na posameznih nivojih uporabili različne rešitve. Za toplotne in hladilne postaje, pripravo sanitarne tople vode in klimatske naprave so uporabljeni preizkušeni krmilniki, ki omogočajo veliko prilagodljivost pri razvoju, hkrati pa zagotavljajo zanesljivo in učinkovito obratovanje in pripravo energetskih medijev za zgradbe.

The Honeywell Lynx programmable controller with Bacnet communication was chosen for room regulation due to its adaptability. Room control is completed with lighting control, allowing local settings and integration into the CCS system.

The CCS also incorporates SCADA-based iFIX software, which coordinates subsystems like external blind positioning relative to sunlight. Ethernet and serial subnetworks provide the communication backbone.

MePIS Energy, an extension of the CNS, monitors and optimizes energy consumption and costs.

The system ensures efficient monitoring and energy-saving management of all energy systems across both faculties.

The CCS also guarantees reliable and user-friendly room controls, while dynamic connections to the access control system ensure high energy efficiency, only maintaining comfort settings when rooms are in use. The system offers easy management of spaces and devices, contributing to optimal operations.