A: Separate development from scratch is not necessary. The mainstream approach involves using standard protocols combined with an intermediate layer to bidirectionally connect equipment status, work order progress, and ESD electrostatic monitoring data. Implementation can be viewed in several layers.
1. Clarify data flow first. ERP manages orders, materials, and BOMs. MES handles work order scheduling and process traceability. The Kanban system is responsible for real-time equipment status and on-site visualization. Integration does not mean merging the three systems into one; rather, each system accesses only what it needs. The Kanban pulls work orders and production cycle data from MES, and retrieves equipment ledgers and maintenance plans from ERP. Conversely, it writes back equipment downtime, ESD alarms, and OEE data to MES for analysis. Defining the data flow before discussing interfaces avoids many detours.
2. Select the appropriate interface method. There are three common paths: OPC UA or Modbus to collect equipment layer data followed by reporting to the Kanban; RESTful API or MQTT for message passing between systems; and database intermediate tables suitable for older ERP systems to perform scheduled synchronization. Newer MES systems generally provide APIs. Older systems should use intermediate tables or message queues rather than forcing direct connections.
3. ESD electrostatic monitoring requires specific attention. Due to high real-time requirements, this data should be collected via an independent channel. Grounding resistance, ionizer fan status, and personnel wristband alarms should be mapped to the Kanban by workstation ID. These events are then pushed to the quality module of the MES as discrete events, rather than sharing the same link as production volume data.
4. Master data alignment is critical for success. Equipment codes, workstation IDs, and work order numbers must be consistent across all three systems. If the equipment displayed on the Kanban does not match the equipment ledger in the ERP, the integration is ineffective. A code mapping table should be prepared before system launch.
Summary recommendation: Define data flow first, select interface protocols next, route ESD data through an independent channel, and align master data prior to implementation.