Melitta Europa GmbH & Co. KGMelitta has been involved for over 100 years in producing and pro­

viding services to make life more enjoyable and comfortable. What

comes to mind is the Melitta filter paper which goes back to the

original idea by Melitta Bentz. In the year 1908, she invented the

first filter papers for coffee and thus laid the cornerstone for a very

successful family business. Today, Melitta Europe GmbH & Co. KG –

operating division Coffee / Coffee Preparation of the business field

Coffee and Tea – produces filter bags of all types in Minden. Addi­

tional production sites are in the USA and Brazil, where they produce

coffee machines ( Melitta), tea filters (Cilia), hoover bags (Swirl) and

plastic wraps and bags (Toppits).

We convinced our staff to accept MES as an important tool of

our daily working routine. We would be blind without HYDRA and

could not produce that efficiently to survive in a market where we

need high productivity and also the cooperation of our staff.

Michael Weber, Production Manager at Melitta

The MES Experts!

Energy Management Machine Data Shop Floor Data Shop FloorScheduling

Tool & ResourceManagement

HYDRA Success Story

Task and SolutionIt is essential when manufac turing filter bags to focus

on quality, competitiveness, environmental friendly ness

and innovation. Therefore, Melitta uses the holistic MES

solution HYDRA by MPDV in their production process. To

support the production of filter bags, they work with the

modules Shop Floor Data and Machine Data as well as

Tool & Resource Management. The production orders

generated in the leading SAP system are planned via

a hands­on solu tion for Shop Floor Scheduling in the

MES on the relevant machine or production line.

The operator logs on the upcoming order at the data

collection terminal and sets up the machine. Also,

quantity collection of the machine is directly connect­

ed to the terminal. Thus, HYDRA automati cally collects

the produced quantity and thereby also the machine

status. If the cycle time has been exceeded, HYDRA

automatically identifies a malfunction and asks the

operator to select and assign a reason for the malfunc­

tion from a predefined list. This enables a standardized

evaluation of machine times. The order is logged off

at the terminal upon completion. The amount of pro­

duced parts is transfered to SAP in a subsequent pro­

duction step at the palletizing line.

The collected shop floor data enables the system to

generate meaningful evaluations in real­time, which

provide supervisor and production manager with a

quick and informativ overview of the current situation

or the previous shifts. A central tool is the shop floor

monitor. At a glance, the super visor knows, which

machines are producing, which malfunctions occur

and where each order is produced.

With introduction of the maintenance calendar for

tools, the maintenance intervals now take place after a

predetermined number of cycles, which is supported by

an automatic collection of cycles. This is a great advan­

tage for the production flow, as targeted maintenance

increases machine availability and in addition, costs

for maintenance work are dramatically reduced.

With the implementation of the

HYDRA module Energy Manage­

ment, the energy consumption is

considered to be reduced grad­

ually. HYDRA Energy Manage­

ment makes it possible to collect

energy consumption and per­

formance values as well as

evaluations in conjunction with

Shop Floor and Machine Data. It is then relatively easy

to assess, how much energy is used for the produc­

tion of a certain article. The Energy Management also

provides important information to optimize mainte­

nance cycles, as increased consump tion allows to

draw conclusions on the machine condition.

HYDRA in Use

• Windows Server with Oracle database• Interfaces to SAP• 8 HYDRA Office Clients• 29 HYDRA Shop Floor Clients• More than 30 machines connected

HYDRA Success Story

The MES Experts!© 2018 MPDV Mikrolab GmbH |Doku­Ident: PB MELITTA EN 03/2018.

Reprint (also in parts) only with permission of the publisher. The mentioned product names are trademarks of the respective producers or suppliers. HYDRA® is a registered trademark of MPDV Mikrolab GmbH.

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