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Despite significant investments in ERP systems, many manufacturers still struggle to manage their operations effectively. The root of the problem? A lack of accurate, real-time data from the production floor.
ERP systems are powerful tools - they help manufacturers plan resources, manage inventory, and fulfill orders. But their effectiveness hinges on the quality and timeliness of the data they receive. When that data is delayed, incomplete, or inaccurate, the value of the ERP begins to break down. Unfortunately, this is the reality for many mid-size discrete manufacturers.
A recent customer captures the problem: "We rely heavily on our ERP - but we also don't trust it."
As critical as ERP is, the reality is that these systems were not built to reflect real-time shop floor activity. They also were not built to be used on the shop floor.
Often, the information that bridges the planning phase and execution phase is carried by paper travelers and other manual methods.
Operators are expected to record production output, downtime, and scrap reasons by hand or in a separate terminal, typically after the fact. The results? Data lags, duplicate entries, incomplete visibility, and a lack of confidence in the ERP system's output.
Without reliable shop floor data, manufacturers end up working harder just to keep up. Production managers walk the floor for updates. Schedulers operate blind, unable to adjust for machine downtime or changes in part availability. And decision-makers have little faith in what the ERP is telling them.
When machines are connected directly to ERP systems, everything changes. Instead of relying on manual data collection, data flows automatically from the machines. This means part counts, cycle times, and scrap reasons can be captured and recorded in real time - seamlessly connected to the part operation and word order they are associated with.
Instead of viewing performance at the end of the day, managers and planners get a live window into what’s happening on the shop floor.
Integrating machine data into ERP closes the loop between planning and execution. It enables more accurate quoting based on actual performance, smarter production scheduling based on current machine availability, and faster response to unplanned downtime.
Consider what this looks like in practice:
When business and shop floor are in sync, companies can adapt quickly to changes, reduce lead times, and deliver orders on time, every time.
At MachineMetrics, we’ve built our platform specifically to make machine-to-ERP integration simple, scalable, and fast to deploy. Our platform connects directly to machines, manual equipment and manual stations, automatically capturing real-time data including part counts, cycle times, alarms, and more. We then link that data to work orders, operations, and schedules from your ERP system - without requiring complicated or custom-built integrations.
Our ERP connectors are purpose-built to eliminate the heavy lifting of integration. With support for a wide range of systems - including JobBOSS2, Infor Visual/Syteline/XA, Microsoft Dynamics 365, SAP S/4HANA, Epicor 10, and others.
Once connected, MachineMetrics enables:
Operators can select, start, and complete jobs right at the machine, using tablets with intuitive interfaces that pull directly from your ERP. And because the data is validated and enriched by machine activity, it's more accurate, more timely, and more useful for decision-making.
If you're ready to stop relying on tribal knowledge and start running your operations with a clear, connected view from planning through execution, MachineMetrics offers a practical, scalable way to get there - quickly and without the complexity of traditional MES systems.
Efrem Escobar, General Manager at ABACORP CNC Machined Parts, shares the impact of connecting MachineMetrics and JobBoss2. Watch the full webinar here.
Ready to empower your shop floor?
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