To make a smart factory a reality, machines and systems from all sub-areas must communicate with each other and end-to-end digitalisation must be achieved. The Dürr Group, one of the world's leading mechanical and plant engineering firms together with its subsidiary company, iTAC Software developed a modular solution for manufacturing planning, execution, control, monitoring, optimisation, and predictive analysis. Dürr uses its manufacturing and digitalisation knowledge to combine hardware and software while iTAC Software is a solution provider of Manufacturing Execution Systems (MES). The two companies will display the functioning of newly developed Manufacturing Operations Management (MOM) system at the Hannover Messe trade fair in hall 15, booth E34.

There are three central superordinate control components in every digital factory: MES (Manufacturing Execution System) controls and monitors production, SCADA (Supervisory Control and Data Acquisition) collects and analyses data, and HMI (Human Machine Interface) visualises production and process flow. Until now, these components, for example, the MES sub-segment, were mostly designed as stand-alone solutions. Dürr and iTAC have combined their competencies and merged the functional scopes of MES, SCADA, and HMI into a uniform MOM architecture.

Instead of monolithic individual solutions, the new MOM system relies on micro-services that provide functionality as required. The solution enables a high level of flexibility and consistency and offers many interfaces in terms of interoperability. This was made possible by combining Dürr's DXQcontrol product family with iTAC's iTAC.MOM.Suite. Manufacturing companies, whether manufacturers or suppliers, thus receive a future-proof industrial digitalisation solution with interoperable modules that cover all smart factory functionalities.

Microservices architecture for agile manufacturing
The MOM architecture from Dürr and iTAC is a modular approach in comparison to earlier MES solutions, which were monolithically constructed, meaning that a single software product covered much functionality such as data acquisition or logistics. Multiple microservices act and communicate with each other while performing their tasks independently. Microservices, as distinct to monolithic solutions, provide open interfaces for communication with other services and self-sufficient data storage for flexible deployment.Only necessary modules are installed, making operation more sustainable, as fewer servers are required. The modular design of the MOM architecture increases plant availability since it is less prone to errors than monolithic architectures.

Variable availability: Cloud, on-site, or hybrid
Microservices have the additional benefit of being flexible in their installation on IIoT platforms in the cloud, on-site (on-premises), or in hybrid factory deployments. Clients can employ particular cloud services while implementing other features on-site, for instance, if they have concerns about operational costs or production stability.The hybrid solution is particularly advantageous for large data volumes in the terabyte range. Processing some of the data locally ("on-edge"), i.e., within the local environment, saves time, costs, and energy because not all data sets have to be transferred to the cloud/IIoT platform via many transactions. Moreover, local processing provides the necessary speed for real-time control of manufacturing processes.

Sustainable Production Management
Dürr and its subsidiaries iTAC Software AG and Dualis GmbH IT Solution will present other industry development trends in addition to the MOM presentation at the Hannover Messe trade fair. Another focus is on sustainable and energy efficient production management. Dürr will present its ISO 50001-certified DXQenergy.management software that maps media consumptions throughout the production line, systematically detects consumption anomalies, and consequently identifies potential savings. The GANTTPLAN planning tool from Dualis monitors energy costs incurred during production planning.

Manufacturing Analytics and Intelligence
Dürr and iTAC’s analysis tools use artificial intelligence to improve production quality and availability. They can act as MOM system components. The products evaluate production and quality data, which can detect possible defects or impending wear but also use machine learning to make forecasts. Prevention and prediction services and the integration of edge technologies result in optimisation, increased added value, and data sovereignty.

Advanced Planning and Scheduling (APS)
The Group offers intelligent tools from Dürr, iTAC, and DUALIS as an overall solution for the APS field. These tools plan and optimise production order execution, consider available resources and capacities as well as material requirements and necessary maintenance intervals. The solution has many benefits, such as short delivery times, high delivery reliability, and permanent cost optimisation.

Dürr, iTAC, and DUALIS together at Hannover Messe
More than 4,000 exhibitors will present their solutions on current trends at the major industrial trade fair in Hanover, Germany, where the digitalisation of production plays a central role. Dürr, iTAC, and DUALIS will present end-to-end solutions for a smart factory at their joint booth (hall 15, booth E34) in line with the theme "Real industrial transformation. Digitise today. Enable tomorrow."