Siemens Tech Talk: Scaling Bayer’s Global Manufacturing
From One Plant to 40+ Global Sites: Bayer's Technology Success Story
In this thrilling episode of Siemens Digitalization Tech Talks, we dive into a real-life success story that explores Bayer’s initial implementation of a cloud-based technology solution at a single manufacturing site to its impressive scaling across more than 40 global locations. Join experts Brandon Johnson from Engineering Industries eXcellence and David Kaltmayer from Bayer as they unlock the secrets behind scaling a technology focused on asset performance, data integration and machine learning insights. Discover the challenges faced, the innovative solutions applied and the invaluable lessons learned along the way. Don’t miss out on this exciting and informative episode led by Siemens hosts Don Mack and Jonas Norinder uncovering this inspiring journey of overcoming obstacles and achieving remarkable success.
About the Customer
Engineering Industries eXcellence has reached a pivotal milestone in one of the biggest ongoing rollouts of Siemens Insights Hub (formerly MindSphere) for Bayer Crop Science. The company’s manufacturing is split into two areas – chemical crop protection and row crop seed production. For over 150 years, the organization has worked toward implementing the latest and most innovative technologies and services to improve production processes. The crop science leader chose Engineering Industries eXcellence’s team of Digital Thread experts to implement valuable transformation solutions for improved order management, inventory management, shop floor connection and data recording.
- Agribusiness & Chemicals
- Crop protection chemical manufacturing
- Row crop seed production
- Fungicide, herbicide, insecticide and seed growth products
- Seed trait innovation
Bayer Crop Science’s Need
Bayer Crop Science provides tools and seed products to support sustainable and resilient environments for farmers around the world, however, given the scale of their facilities and output requirements, meeting growing consumer demand has been a challenge. Knowing that optimizing order management and recording analytical data for review is key to increasing efficiency across their global production facilities, the crop science leader sought comprehensive technology solutions to realize this potential. With newly integrated solutions for production systems and shop floor machines in mind, their goal is to create a seamless approach for enhanced site processes.
- Improve inventory management for reduced costs
- Track real-time production data for improved decision-making
- Measure equipment efficiency for increased productivity
- Manage equipment downtime to improve facility operations
- Support proactive maintenance to reduce machine failures
About the Project
Overall Equipment Effectiveness (OEE) is a critical metric for manufacturing and production companies. Given its ability to measure equipment and process efficiencies, it provides quality control for a more productive workforce. In this case, OEE is helping Bayer Crop Science gain visibility on how productive and efficient manufacturing lines are in real time, creating a great basis for comparing metrics between their existing facilities.
Before Engineering Industries eXcellence’s solution rollout, they faced productions challenges which included a lack of visibility on manufacturing lines and the inability to determine inefficiencies. They needed a solution that could help them gain actionable insights using asset and operational data for improved processes. With a goal of having more of their global sites take advantage of new solutions every year, the customer enlisted Engineering Industries eXcellence to step in for even further support than what was already achieved in previous digital transformation projects. Beginning in 2020, our experts implemented new Manufacturing Execution Systems (MES) and OEE solutions across 13 of the customer’s production sites. Leveraging Siemens Opcenter Execution Process and Siemens Insights Hub (formerly MindSphere), along with integrations to Enterprise Resource Planning (ERP), Siemens Opcenter Laboratory (LIMS) and shop floor equipment, our team enabled Bayer Crop Science teams to monitor manufacturing operations in real time, calculate equipment effectiveness and perform downtime analysis. Since then, Engineering IndX has implemented these solutions at over 40 new sites. With the project still ongoing and more sites left in scope, this has been identified as one of the largest rollouts of Siemens Insights Hub in the world. The agrochemical leader can now record machine data, measure equipment efficiency, manage equipment downtime and engage in proactive maintenance as necessary.
Engineering Industries eXcellence was chosen as the primary partner given our deep knowledge within the shop floor and manufacturing space as it relates to Siemens technology. Additionally, our global presence of experts also boosts the availability of resources in reach for the crop science leader’s production facilities around the world. Throughout our projects, our team has provided solution design, solution development, software installation, training and support to ensure that the crop science innovator will be able to confidently take full ownership of their MES and OEE solutions.
- Implemented Manufacturing Execution Systems across 40+ global sites
- Implemented integrated OEE & KPI Monitoring solutions across the enterprise
- Delivered cloud-based, low-code Asset Performance Management applications
- Integrated Laboratory Information Management System to MES
- Integrated existing ERP system to new Manufacturing Operations Management (MOM) ecosystem
- Ongoing end-to-end services covering solution design, software development, system integration and enhancement
Engineering’s Advantage
Our Industries eXcellence team built a scalable and adaptable solution that can be applied globally across both lines of the Bayer Crop Science’s agricultural business. As their strategic partner for Industry 4.0, our team will continue to work with them to add enhancements and functionalities. By supporting all phases of the lifecycle for this initiative including consulting, requirements gathering, design and technical system deployment knowledge, users at over 40 seed site facilities worldwide and counting can take advantage of streamlined operations for refined production.
