AI is the second step – not the first 

In manufacturing practice, it is becoming increasingly clear that artificial intelligence does not unfold its benefits at the beginning of digitalization but rather builds on it. AI approaches can only fully leverage their potential once production processes are transparently mapped, data is consistently available, and systems are effectively integrated. Without these foundations, AI often remains an isolated experiment – technically interesting, but without any lasting impact on everyday production. 

Holistic approach instead of AI as an end in itself 

By joining SEF Smart Electronic Factory e. V., iTAC brings a holistic approach to digitalization to the network. The company has many years of experience with integrated MES and MOM systems and supports the digitalization of production along the entire value chain. Artificial intelligence is understood as a tool that builds on a stable and integrated system landscape. 

When used correctly, artificial intelligence opens up considerable potential in manufacturing: it can help to make production knowledge more usable, identify correlations more quickly, and make more informed decisions. The prerequisite is that processes, systems, and knowledge are not isolated from one another, but are linked together. 

“Many companies currently want to integrate AI but the conditions must be right,” says Andreas Zerfas, VP Product Management at iTAC Software AG. “Our approach is to think about digitalization holistically and use AI as a meaningful addition to existing production systems. In the SEF, we can deepen and further develop this perspective together with users and other partners.” 

iTAC provides integrated manufacturing management solutions that combine production planning, control, analysis, and knowledge utilization in a single system. Based on MES and MOM structures, production processes are mapped transparently, real-time data is made consistently available, and linked to documentation and empirical knowledge. AI-supported functions build on these foundations – for example, for the context-related provision of information, the analysis of deviations, or the support of operational decisions. This results in an inte-grated approach. 

“An MIT study from 2025 shows that 95 percent of AI pilot projects in companies fail. This is due to a lack of benefits and poor understanding of context. Our collaboration with the SEF and its members is a strategic step for us to jointly implement projects with real and economic benefits for future users,” explains Martin Heinz, CEO at iTAC. 

With the addition of iTAC, SEF Smart Electronic Factory e. V. is strengthening its expertise in the field of integrated production systems and continuing its mission to support small and medium-sized manufacturing companies on their path to effective, sustainable digitalization.

The iTAC.MOM.Suite closes this information gap. It is a comprehensive manufacturing management system that covers all requirements, including production and quality management, traceability and real-time control of production processes. A total of 1,700 devices are now connected to the solution at Alps Alpine – from SMT to final assembly.

Connecting machines and systems from different manufacturers
A core element of the new solution is the iTAC.SMT.Edge. In SMT production, there are machines and systems from different manufacturers and of different ages that use different communication methods. This makes data transfer and analysis more difficult.

iTAC.SMT.Edge makes it possible to connect machines and systems from different manufacturers in a bidirectional network. The data is consolidated on the shop floor by means of an edge solution-based machine integration platform and distributed to the higher-level company systems, such as the MES, via a direct interface.

Edge technology provides a simple way to collect, link and analyze data from all SMT machines in real time. This means that important key figures such as cycle times and productivity can be compared not only within a plant, but also across several locations.

Alps Alpine started out by using the iTAC.SMT.Edge at its plant in Hungary. After successful testing, the solution was rolled out to other locations such as Mexico, China and Japan.

Immediately identify errors using real-time data 
iTAC.SMT.Edge enables a high level of data availability, among other things. Alps Alpine particularly appreciates the availability of real-time data, which significantly improves the traceability of parts and components within the company. “With the previous system, tracking data was very difficult and time-consuming. Now we have instant access to all the information we need,” states Ákos Varga. This considerably simplifies and speeds up the internal troubleshooting process.

This form of traceability is equally important for OEMs. “In the event of complaints, the affected component must be found as quickly as possible – regardless of whether it is still in the warehouse or has already been installed in a vehicle. Thanks to the iTAC solution, the time needed for such investigations has been significantly reduced. What used to take days can now be determined in a few minutes,” says Ákos Varga.

Outlook: further automation and predictions 
Alps Alpine has laid the foundation for future automation with the iTAC.MES.Suite and the iTAC.SMT.Edge solution. Planned expansions in the areas of data analytics, predictive maintenance and anomaly detection show that automation is becoming increasingly important in order to overcome the shortage of skilled workers and to make production processes more resilient and efficient. “We are striving for a production system in which machines independently detect problems and provide early warnings of failures. Further development towards more automated production ensures long-term competitiveness in the company,” explains Ákos Varga.

The iTAC.MOM.Suite maps all processes – from production planning to quality control. The Manufacturing Operations Management system combines Manufacturing Execution System (MES) functions with real-time solutions for controlling, optimizing and forecasting production processes. It has all the necessary functions for networking and automating processes. The open and service-oriented architecture facilitates data exchange and forms the basis for seamless integration into existing platform concepts. The microservices approach makes it easy to expand the system with new functionalities as needed.

MOM with all components for comprehensive production optimization
The iTAC.MA.Suite, which can be seamlessly integrated into the MOM system, expands the scope of the solution with comprehensive analyses – both real-time evaluations and in-depth examinations of historical production data. This enables companies to understand, evaluate and improve their processes.

When it comes to production planning, the Advanced Planning & Scheduling (APS) service from DUALIS is an integral part of the iTAC.MOM.Suite. It enables optimized production planning, considering factors such as resource availability and bottleneck analysis. The software helps companies to make their production processes more efficient, shorten throughput times and meet delivery deadlines.

With its solution portfolio, iTAC addresses all manufacturing industries. For the needs of the process industry, the software solutions from Accevo are used. The company specializes in industries such as pharmaceuticals, food and fast-moving consumer goods and ensures that manufacturers achieve greater efficiency, traceability and compliance. In addition, Accevo offers Electronic Batch Records (EBR) to support pharmaceutical production with automated data collection and regulatory compliance.

“In the Dürr Group, we are focusing on bundling digital expertise in order to provide comprehensive and customized systems for all manufacturing industries. The iTAC portfolio shows how specialized solutions can be intelligently linked, saving our customers the time, effort and costs that would arise from using many individual software solutions,” explains Martin Heinz.

Andreas Zerfas is head of Product Management at iTAC and is thus also responsible for the continuous optimization and alignment of the product strategy, which includes the consolidation and integration of Cogiscan, ANT Solutions and DUALIS technologies into iTAC's existing ecosystem. 

Cogiscan provides track, trace and control solutions for electronics manufacturing that enable seamless traceability in production. ANT specializes in smart factory solutions for the FMCG and pharmaceutical industries. DUALIS develops advanced planning and scheduling (APS) solutions for precise production planning and optimization. 

“The future lies in holistic platforms with ecosystems that support industrial companies in the digital transformation of manufacturing processes and offer modular, scalable solutions to solve daily challenges as needed. I am very pleased to be able to contribute my experience to iTAC again,” says Andreas Zerfas. 

Between his previous and current roles at iTAC, the expert worked for German Edge Cloud as Chief Technology Officer (CTO) Digital Industrial Solutions. There he played a key role in the development of the ONCITE Digital Production System (DPS) platform.

“Modern battery production is complex. It requires high-precision processes and at the same time a high production speed in order to meet demand. At the same time, it is subject to strict industry-specific quality requirements. For our customer project, for which we are currently setting up the production lines, an MES/MOM is indispensable. A 4-month selection process convinced us that the iTAC.MOM.Suite meets all the technological requirements that are crucial for the production of battery modules and battery packs,” explains Martina Raguž, IT Project Manager at Rimac.

The iTAC.MOM.Suite production management system from iTAC enables the mapping, control and planning of the entire production process and ensures active traceability. "In the challenging production of battery cells, materials are used that are difficult to process and sometimes highly dangerous. To minimize risks and avoid errors, seamless traceability and comprehensive quality analyses are essential. This enables quality and performance characteristics as well as all standards and specific requirements to be met,” says Diogo Oliveira, Sales Manager MOM EMEA at iTAC Software AG.

Greenfield development – designed from scratch
One special feature: the shop floor at Rimac is a greenfield site, which means that everything can be “redesigned”. This offers the possibility of creating the entire production infrastructure from scratch in a new production environment. As no existing systems have to be integrated and no compromises have to be made with the IT architecture, the MES/MOM system can be perfectly tailored to the specific requirements of modern battery production at Rimac right from the start.

The go-live of the system for the battery pack production line is scheduled for the end of April 2025 and for the module production line for the end of July 2025.

And Rimac is also well positioned for the future “In addition to the functionalities of the iTAC software that are decisive for us, the architecture is an important feature for us. Thanks to the open, scalable platform and microservices, we are also equipped for possible expansions,” emphasizes Martina Raguž.

“We have successfully established iTAC in the market as a MOM provider in recent years. A MOM goes far beyond the classic MES functions by integrating all production and business processes, creating a consistent database. In response to of the increasing complexity in the manufacturing industry – from global supply chains to shorter product life cycles and individual customer re-quirements – a MOM is the holistic platform for meeting these challenges. I will continue to consistently pursue this successful path with my team and develop new functionalities, for example in the field of AI,” says Martin Heinz.

Martin Heinz has extensive technical and strategic experience in the areas of production, logistics and industrial software solutions. He studied industrial engineering and holds an Executive MBA from the THM Business School. He began his career in 1996 in the automotive supply industry before taking responsibility for production and purchasing at a leading MR sensor technology company in 2000.

Martin Heinz has been part of iTAC Software AG since 2003 and has held numerous management positions in the company during this time, including Vice President Product Management and Vice President Operations. Since 2011, he has held the position of General Manager of the D-A-CH division (Germany, Austria, Switzerland), driving strategic and operational development in this role. He has been a member of iTAC's Management Board since 2020 and was appointed Chairman on January 1, 2025.

Furthermore, Martin Heinz has been a member of the management board of DUALIS GmbH IT Solution, a subsidiary of iTAC Software AG, since 2017. Martin Heinz is also actively involved in various industry associations, such as the ZVEI (electronic and digital industries) and the VDMA (German Engineering Association), as well as in working groups on the topics of traceability, MES and Industry 4.0. 

iTAC is consistently pursuing innovation and its iTAC.MOM.Suite is a development of MES that opens up a new dimension in production control. By using IIoT technologies, the solution creates a seamless link between analysis, networking, and automation. Its ability to control and monitor production in real time minimizes errors and avoids downtime. A key advantage is its microservices architecture, which provides functionalities as required, promoting maximum flexibility. 

iTAC has also introduced the iTAC.MA.Suite, which integrates AI-supported analyses. It enables real-time and historical analyses at machine, line, and shopflor level, allowing companies to monitor and optimize their production processes with high precision in a dashboard. Real-time metrics enable proactive data-driven decisions, while machine conditions can be predicted, and production quality can be improved. 

In addition, iTAC offers flexible deployment options to meet different customer requirements across a wide range of industries, including on-premises, cloud-based, and hybrid models. The hybrid model uses edge technology to process data locally and it only transfers critical information to the cloud, maximizing cost efficiency and accelerating data processing. 

“iTAC Software solidifies its leadership in the market through its relentless commitment to innovation and excellence. By integrating cutting-edge technologies, such as real-time analytics, artificial intelligence, and machine learning, the company enhances operational efficiency and ensures rigorous compliance with industry regulations. Its strategic alignment with customer needs and proactive engagement in feedback loops reinforce its reputation as a reliable and agile partner. Through continuous advancements and tailored solutions, iTAC Software stands at the forefront of MES, driving transformative improvements and setting the benchmark of manufacturing excellence in the global market,” explains Ain Sarah Aishah, best practices research analyst at Frost & Sullivan.

“Smart manufacturing, in other words essentially intelligent production, involves the integration of modern digitalization and automation solutions as well as the use of artificial intelligence to make production processes more efficient, flexible, adaptable and resource-saving. The goals in battery production, for example, are real-time traceability and AI-supported data-driven decisions to improve quality and reduce waste,” explains Martin Strempel, Business Development Manager Data Analytics at iTAC.

In a presentation at MESA International's virtual event “Smart Manufacturing Now!”, the expert will use iTAC's “Manufacturing Analytics Control” product line to demonstrate how crucial analyses are for process optimization. 

iTAC is a MESA member and sponsor of the event. “We are looking forward to taking part in this prestigious event. The international exchange allows us to think outside the box and jointly develop new ideas for more efficient, more sustainable and higher quality production processes in various industries,” explains Martin Heinz, member of the iTAC Software AG Management Board. 

More information can be found here.

In the “Hype Cycle for Revenue and Sales Technology, 2024”, iTAC is positioned as a Sample Vendor in the “Composite Applications” segment. We believe that iTAC is therefore setting a good example in this area. “Composable stands for a modern IT architecture concept in which systems and applications are composed of modular, reusable and independent components. These components can include different types of software modules, microservices, containers or applications and can be developed using different technologies and platforms. They are designed to be easily combinable, interchangeable and scalable in order to be able to react quickly to business requirements and market changes. “These trends and the continuing digitalization and automation in the manufacturing industry are driving the development of MES/MOM systems. The switch from monolithic systems to microservice-oriented architectures therefore enables greater independence, flexibility and agility,” explains Martin Heinz, board member of iTAC Software AG. 

The Manufacturing Operations Management solution iTAC.MOM.Suite works according to this principle, setting new standards in the manufacturing industry. The MOM combines Manufacturing Execution System (MES) functions with real-time solutions for controlling, optimizing and forecasting production processes. It has all the necessary functions for networking and automating processes. The open and service-oriented architecture simplifies data exchange and forms the basis for seamless integration into existing platform concepts. The microservices approach makes it easy to add new functionalities as required. 

Martin Heinz says: “We think the recognition in the Gartner report confirms that our production management system is fit for the future.“

Read the full report here.

The Asset Analyzer, a tool from the "Manufacturing Analytics Control" product family, helps companies to identify quality problems in production and increase overall efficiency. The solution can be used across all industries, for example in the automotive, electronics and medical sectors, but also in areas such as injection molding, metal processing and battery production. 

Everything in sight – automatic error detection through AI 

The Asset Analyzer is a tool or dashboard that enables performance analysis of the entire production environment. "This gives companies a clear insight into current and past performance, which is particularly beneficial for critical machines and processes. Operators can react quickly and efficiently to deviations and gain a comprehensive understanding thanks to the holistic view. It is no longer necessary to call up several systems, as the information can be found centrally in a dashboard. This saves time when searching for deviations and increases transparency at the same time", says Martin Strempel, Business Development Manager Data Analytics at iTAC Software AG. 

One particular advantage is the proactive solution to quality problems. Quality parameters can be managed in real time and an AI engine automatically detects errors, for example in electrocoating. Real-time notifications via MS Teams provide information in the case of alarms, events and abnormal behavior, resulting in fewer errors in the production process. 

The solution supports the intuitive retrieval of machine or process data in the dashboard. Access to your own data is made considerably easier, as information from various machines and process steps in the production environment can be retrieved quickly and easily. 

Applicable without technical knowledge 

A key advantage of the Asset Analyzer is its user-friendliness. It is designed for process operators, engineers and management – not just IT or AI specialists. No special skills or knowledge are required to perform in-depth analysis. Dashboards can be configured within minutes. The solution is globally scalable. 

"Many other tools are complicated to use, require special expertise and are often not designed to analyze the entire production environment. In addition, they often have manufacturer or hardware dependencies. Our aim is to provide tools that are not only powerful, but also quick to implement and, above all, easy to use. With the Asset Analyzer, we are paving the way for a comprehensive understanding of performance and thus for higher productivity and quality," says Martin Strempel.

MOM systems with SCADA and APS functionalities, such as those offered by iTAC, the parent company Dürr and the subsidiary DUALIS in combination, offer various advantages over traditional MES. The switch from monolithic systems to microservice-oriented architectures enables greater flexibility, scalability and agility in the production environment.

Thanks to the modular structure of the MOM, companies can select specific functions from the standard portfolio in a process-oriented manner, configure them as required and – if necessary – adapt them in order to optimally integrate the processes and achieve the desired benefits.

From MES to MOM

"The switch from MES to MOM brings significant benefits for production management and the supply chain. In times of increasing threats to companies from criminal hackers and institutions, future-proof MOM systems must now also be developed, integrated and operated with a strong focus on IT security. By introducing security measures in all aspects, companies can achieve a secure, robust and trustworthy manufacturing IT landscape that meets the requirements of a modern factory," says Volker Burch.

iTAC ensures that security aspects are integrated into the process right from the start. From development to implementation and operation of the iTAC.MOM.Suite, clear guidelines and state of the art standards are followed. A holistic approach – from architecture and software design to implementation, testing and deployment – takes the relevant security aspects into account at every stage and is supported by established, audited processes and tools. While there used to be common security vulnerabilities in the development of software, these are now largely eliminated thanks to the support of tools that provide early warning of potential threat scenarios.

Laws and guidelines provide a new framework

There are also various efforts and measures on the part of legislators to strengthen the resilience of organizations to cyber attacks and to minimize the impact of security incidents. The Cyber Resilience Act is currently gaining in importance in this context.

Volker Burch explains: "The Cyber Resilience Act is a clear call to action that requires companies to strengthen their security measures and proactively address cyber threats. By implementing cybersecurity best practices, organizations can not only protect their data and operations, but also protect their investment and reputation by building trust with customers. Otherwise, security incidents cause potential financial losses and reputational damage. In addition, the Cyber Resilience Act offers companies the opportunity to differentiate themselves from competitors by demonstrating that they are actively addressing cybersecurity challenges and continuously improving their systems and processes."

Compliance with guidelines and laws is also of global relevance, as Volker Burch points out: "By investing in secure systems such as our MOM, companies can not only protect their own interests, but also help to strengthen the overall security of the digital industry."

Last year, Dürr, GROB and Manz formed the first European cooperation to emerge in the field of production technology for lithium-ion batteries – with the aim of establishing themselves as suppliers of complete battery production systems. Together with other partners, they offer the entire plant and digitalization technology for the production of vehicle batteries from a European source. The value stream covers all stages from electrode production to battery pack assembly.  

End-to-end digitalization for battery production

In this context, iTAC is the expert for the digitalization of processes. The iTAC.MOM.Suite production management system from iTAC and Dürr can map all processes end-to-end. It enables the mapping, control and planning of the entire production process as well as traceability. 

Traceability is one of the most important building blocks here. “In the demanding production of battery cells, materials are used that are difficult to process and sometimes very dangerous. To minimize risks, avoid errors and optimize processes, end-to-end traceability and quality analysis are essential. In this way, quality and performance characteristics as well as all standards and other requirements can be met,” explains Martin Heinz, board member of iTAC Software AG.

In addition to the traceability functionality, the iTAC.MOM.Suite offers tools such as the iTAC.BI.Service and Quality Management. These provide analysis and reporting functions for all product-related quality data. This allows the quality of the electrodes to be evaluated and analyzed throughout the entire process. “Defects, such as holes that can occur in the coating production process, are documented, can be traced and thus sorted out in later process steps. Transparency in production is possible with both business intelligence and real-time dashboarding. This makes optimization potential visible,” says Martin Heinz.

The use of data analytics tools ensures that changes and anomalies are detected at an early stage, thus creating the basis for predictive control of production processes (predictive quality) in battery production. In addition to the lithium-ion battery cell, other cell types can also be mapped in the iTAC solution.

At the same time, it is important to ensure a high level of efficiency through sophisticated production planning in order to meet the continuously increasing demand. In combination with the Advanced Planning and Scheduling System (APS) from DUALIS integrated in the iTAC.MOM.Suite, optimized production planning based on actual and limited capacities is possible. This creates a holistic planning approach that takes all resources (machines, processes, tools, materials, personnel) into account and ensures their optimal use.

Martin Heinz explains: “In combination with the system technology, we are working with Dürr and the other partners to enable manufacturing companies to increase their production capacities for batteries quickly and safely. They don't have to spend time searching for several partners who ultimately offer isolated solutions, which can be at the risk of process efficiency and cost-effectiveness.”  

MES expanded into an open microservice-based system
Limtronik aims to be highly adaptable and flexible through the digitalization of processes. MES solutions have been an important building block for intelligent factories and digital manufacturing for many years.

"As a stand-alone proprietary system and with its classic range of functions, an MES no longer meets the requirements of the increasingly networked factory. We have therefore developed our MES into the iTAC.MOM.Suite, a Manufacturing Operations Management System. The open MOM acts as a holistic, flexible production management system and offers functions for controlling, optimizing and forecasting production processes," explains Martin Heinz, Board Member of iTAC Software AG.

The MOM system is therefore a further development of the MES – designed for predictable production that makes use of the latest IIoT technology. It brings formerly separate worlds together. The iTAC.MOM.Suite has all the necessary functions for networking and automating processes. It has a modular and scalable structure and can be seamlessly integrated into companies' digital platform strategies thanks to its openness. The microservices architecture makes it possible to provide functionalities in line with requirements.

Low-code and AI methods increase the level of digitalization
"While iTAC's MES has solved classic requirements such as traceability and production management in our company for many years, today it is also important to link production processes and digitalize them end-to-end. iTAC has created a holistic platform for this with the MOM," says Gerd Ohl.

The traceability, production planning and control functions are still essential, but have been expanded to include new applications, including AI and low-code methods. The result is a flexible yet highly standardized system that is also fully scalable and easy to roll out thanks to its template properties. Gerd Ohl explains: "Over the years, we have successively connected the SMT production lines, several assembly lines and machines for electrical testing in the test field to the iTAC solution and are adding more and more modules and functionalities. In the near future, for example, we would like to introduce a QM module for analyzing and reporting quality data."

The aim is to be able to visualize and analyze the data automatically and in real time in production. The introduction of low-code and AI-based functions for the faster provision of applications is also to be implemented together with iTAC. In addition, the APS from iTAC’s subsidiary DUALIS will be used to optimize and save time in planning processes. "The MOM solution enables us to react flexibly to market requirements. We can continue to increase the degree of digitalization as required and are therefore prepared for the future," says Gerd Ohl.

"Manufacturing Analytics Control" can be used to complement the Manufacturing Operations Management system iTAC.MOM.Suite, which is designed to plan, control and monitor production processes in real-time. However, it can also be implemented as a stand-alone solution. 

The iTAC.MOM.Suite is designed to be modular and scalable and can be seamlessly integrated into companies' digital platform strategies thanks to its openness. The comprehensive platform's microservices architecture makes it possible to provide functionalities according to individual demands. The existing functionalities for traceability, production planning and control are gradually being expanded to include new applications, including AI and low-code tools. 

AI increases industrial value creation 

In addition to intelligent analysis, iTAC also focuses on efficient interaction between human and machine. The company has integrated an AI chatbot as a plugin for the Workbench. The multimodal language model is able to understand the technical documentation based on specific data stored by iTAC and provide appropriate, technically-savvy answers to questions. It can also recommend the right API for a particular use case and even generate script code for a use case based on the API documentation and input. In addition, the tool offers translation capabilities for over 140 languages. 

"Users can chat with the system and ask questions about specific functionalities or interfaces, for example. If an answer does not fully resolve the issue, further details can be called up. Among other things, we have stored all the iTAC.MOM.Suite manuals on which the information is based. And the system has the ability to understand and generate code itself. In this way, artificial intelligence helps to significantly increase industrial value creation," explains Peter Bollinger. 

iTAC thus combines artificial intelligence with a holistic production management system - always in compliance with the highest safety criteria and guidelines. 

The company offers solutions for all industries across the entire production chain. These range from simulation including production planning with the solutions of iTAC subsidiary DUALIS to Manufacturing Analytics Control. Together with ANT Sp.zo.o, a company that has been part of the Dürr Group since summer 2023, the challenges of high-volume production environments, such as in the food and cosmetics industries, i.e. in the fast-moving consumer goods (FMCG) sector, can also be overcome. The industrial software specialist's solutions are also used in the pharmaceutical industry, where they help to increase efficiency in the production of medicines, vaccines and food supplements. 

Together with DUALIS and ANT Sp.zo.o, iTAC will be presenting combined software solutions at HANNOVER MESSE, which will be demonstrated at the joint booth (Hall 15/Booth F13). They provide answers to current challenges in times of digitalization in the industry.

iTAC's software solutions are the result of more than 25 years of experience. The company always takes the most important trends into account in the product development process and ensures a high level of user-friendliness.

Strong focus on customer needs

"In close cooperation with our customers, we develop customized solutions with clear roadmaps that ensure the successful achievement of objectives and at the same time create trust, resulting in long-term partner relationships," explains Martin Heinz, board member of iTAC Software AG.

Chandni Hussain, industry analyst at consulting firm Frost & Sullivan, emphasizes: "iTAC Software’s team of experienced specialists in professional services guides customers through the entire process and ensures that they receive support. Customer satisfaction is the top priority when project managers, consultants, and support staff optimize customers’ productivity and long-term competitiveness.

Leading MOM for the medtech and life sciences industry

The MES/MOM solution from iTAC enables manufacturing companies to increase the quality and throughput of their production. It is used in various industries – from energy to electromobility. It also enables companies in the medtech and life sciences sectors to remain competitive and build up innovative strength.

"iTAC is the leading MES/MOM provider in the medtech and life sciences sector. The iTAC.MOM.Suite enables the control, optimization and prediction of production processes using AI in real time. This is what manufacturing companies need for the digital transformation and to overcome the challenges of today and tomorrow.  The company combines a high level of technological innovation with best practice. iTAC has earned a reputation for offering the best overall solution on the market. These factors led us to present the award," says Marcos Ainchil, Best Practices Research Analyst at Frost & Sullivan.

Each year, Frost & Sullivan presents a "Company of the Year Award" to the organization that demonstrates outstanding performance in terms of growth strategy and execution in its field. The award recognizes a high level of innovation in products and technologies and the resulting leadership position in terms of customer value and market penetration. The industry analysts compare market participants and measure performance through in-depth interviews, analysis and extensive secondary research to identify best practices in the industry.

MES/MOM facilitates production planning across divisions

Among other benefits, the standardized MOM allows for the analysis of unplanned downtimes, continuous improvement of machine run times, and the implementation of systematic corrective actions. Martin Heinz, board member of iTAC Software AG, highlights, “The detailed planning of manufacturing and assembly as well as the integration of the quality division and logistics are important features of our new system. For that reason, the new solution also includes our subsidiary DUALIS’ production planning software, GANTTPLAN, and space planning software, AREAPLAN.” This enables comprehensive production planning across divisions and consideration of the entire value chain. The space planning tool supports effective schedule and capacity planning in assembly, optimizing space utilization on the factory floor.

First successful rollouts in the Dürr Group

In spring 2023, the new MOM was rolled out at Group subsidiary HOMAG’s Holzbronn and Schopfloch sites, as well as in parts of Dürr Systems AG in Bietigheim-Bissingen. The core modules focused on machine connectivity and order data acquisition. Jens Held, Head of Operations at HOMAG Plattenaufteiltechnik GmbH in Holzbronn, emphasizes, “The MOM is an important building block for our internal digitalization right down to the shop floor level. At the same time, it makes our processes much more robust and transparent, which ultimately also increases customer satisfaction.” More factories are scheduled for integration in the coming months. The standardized MOM introduction supports digital transformation within the Dürr Group, emphasizing the increasing digitalization of the entire value chain. It also creates synergies, so all Group divisions can benefit from shared system developments.

Simultaneously, it provides Dürr and iTAC with a best practice reference for other machine manufacturers. Dr. Arndt Eigeldinger notes, “A MOM used by the provider itself has a completely different impact. It is tailored and tested to meet the exact needs of the industry. Our customers can benefit from our hands-on experiences.”

Production processes can be controlled and monitored in real-time

Efficient and transparent production at Eberspächer is at the heart of the company's ability to adapt to dynamic market developments. Customer requirements are increasing rapidly and quality control must fulfill more complex tasks with maximum reliability.

To provide technological support, the company has implemented the iTAC.MES.Suite at its sites in Landau and Tianjin. The solution offers comprehensive downward-compatible ERP, PLM and system interfaces. SAP is connected to the MES as the ERP system. Among other things, the ERP system supports automatic feedback on the production status. Production processes can be controlled and monitored in real-time with the iTAC.MES.Suite. This creates the basis for the direct execution of production orders and dynamic reactions to changes.

Zero-defect strategy – with traceability and process interlocking

The MES ensures the traceability that is essential in the Automotive Electronics business unit. "Our electronics production is becoming more efficient. At the same time, a single defect can have more far-reaching consequences than ever before. Our customers expect components that are placed on a PCB to be traceable. End-to-end traceability is therefore crucial in order to minimize risks, prevent errors and optimize processes", explains Daniel Ignor, Local Process Expert in the Automotive Electronics area of the Eberspächer Group. The MES and its traceability function can be used to track the entire product manufacturing process. This is made possible by tracing all production and process data. Based on this information, process interlocking can be carried out during the ongoing production process.

With its real-time process interlocking mechanisms, the MES contributes to zero-defect production. "Thanks to traceability and process interlocking, we have seen an improvement in quality during series production. We have also been able to save resources in root cause analysis. Further advantages lie in performance monitoring, data collection and evaluation," summarizes Sergej Gertje, Head of IT & MES for Automotive Electronics at Eberspächer.

In line with the digitalization strategy at Eberspächer, those responsible are planning to further expand the area of application towards BI tools and IIoT as well as sensor data evaluation for the purpose of predictive maintenance.

"Manufacturing Analytics Control" combines software products from iTAC and its subsidiary Cogiscan. A central component is the streaming engine, which can process and link data from multiple sources in real-time, and then analyzes the performance of the entire manufacturing environment. "We are paving the way for comprehensive performance understanding. This supports operational planning, enables the identification of room for improvement and ultimately contributes to a more efficient and profitable production," explains Martin Heinz, board member of iTAC.

Providing clear insights into current and past performance, especially for critical machines and processes, the predefined key performance indicators (KPIs) allow companies to closely monitor and evaluate performance parameters. In addition, process owners can quickly identify deviations from desired setpoint and respond to them efficiently. This helps to minimize production downtime and optimize operational performance.

The ability to customize dashboards allows companies to visualize relevant KPIs and data according to their specific needs and priorities – the basis for tailored analysis and action-driven decision making. Widgets from different products can be combined in a dashboard as desired. For example, widgets for the analyses of ovens, nozzles or feeders can be selected and arranged via drag-and-drop. Another unique selling point is that machine data from upstream and downstream processes can be compared directly with each other, e.g. to run an analysis in real time. Using AI, the measurement data is correlated with the data from the AOIs (Automatic Optical Inspection) and SPIs (Solder Paste Inspection) and then mapped in a heat map.

Easy implementation and workload reduction on multiple levels

"Manufacturing Analytics Control" offers various advantages for creating added value from data and can be deployed immediately, and is a simple add-on for companies with existing infrastructure. Implementation and usage are very simple: no data scientists and no programming experience are required to get started.

The solution offers standard out-of-the-box use cases that are specifically tailored to the requirements or needs of different industries. Connectivity is ensured so that fast and straightforward connections to machines can be established: no specialized connectivity engineering team is required.

The data model has already been successfully tested in various industries. It includes comprehensive data checks, error checks, interpretations, and standardized evaluations. These functionalities serve not only to ensure quality, but also to relieve the reporting team and the data collectors.

Simplifying the tasks of data engineers by making machine data interpretable – the solution combines data from machine with necessary contextual information so that unstructured data becomes structured. Furthermore, this data is transformed into actionable workflows, with interfaces such as MS Teams to enable real-time control of actions, data and machines. It also opens the way for closed-loop control and proactive problem management. Further value can be created from the data using AI and adding AI/ML to workflows is easy.

"Companies can profit from the advantages at the push of a button, for example, quality assurance, increased overall efficiency in production, and reduced workload for employees," Martin Heinz summarizes.

After graduating with a degree in industrial engineering, Andreas Eckert began his professional career at Deutsche Telekom. In 1998, he switched to Software AG, where he held various positions in Controlling at the national level and, since 2007, at the international level with a management function. Most recently, Andreas Eckert was responsible for Finance & Controlling in the DACH and EMEA EAST regions and led a team of 35 employees. He was also the head of Controlling for Software AG's global Professional Services business.

In his new role as CFO of iTAC Software AG, Andreas Eckert is responsible for the development and implementation of the company's long-term financial strategy. "I am very much looking forward to my new task. Together with my colleagues on the Management Board, Peter Bollinger and Martin Heinz, I am pursuing the goal of further strengthening the company's growth and profitability and expanding its market position. Our joint mission is to establish iTAC as a leading player in the MOM segment and to help shape the next industrial revolution with our solutions. With the Dürr Group as our holding company, we live a strong partnership and can always rely on support.", explains Andreas Eckert.

"The future challenges can only be solved with open software solutions and microservices architectures," explains Martin Heinz, board member of iTAC Software AG, and continues: "Flexible systems are required in order to be able to react quickly to changes. A traditional monolithic software architecture is too limited in this respect. This is because the components are in part interconnected and interdependent. Modern production therefore needs a holistic manufacturing management system, a MOM."

Where the MES reaches its limits – that's where the MOM begins

A MOM system is a further development of an MES – designed for predictive production that makes use of the latest IIoT technology. It brings previously separate worlds together. The iTAC.MOM.Suite has all the necessary functions for networking and automating processes. It is modular and scalable and, thanks to its openness, can be seamlessly integrated into a company’s digital platform strategies. The microservices architecture makes it possible to provide functionalities tailored to specific requirements.

The MOM solution enables real-time control, optimization and prediction of production processes using AI. It combines the typical MES functions with solutions for control, planning and analytics as well as IIoT capabilities. The MOM system functionally covers all processes that take place on the shopfloor, i.e. in the area between the machines and the ERP system. In addition, it offers the connection of interfaces to upstream systems of factory planning and design (such as APS, operational floor space planning, etc.) as well as to higher-level systems (ERP, PLM, etc.).

The software is designed for discrete manufacturing – from single piece to batch to mass production – and can be run on-premises, hybrid or in the cloud. It is used globally by companies in a variety of industries, including automotive manufacturers/suppliers, electronics/EMS/TC, medical, metalworking, and energy. Even in new markets such as e-mobility, iTAC's MOM solution maps the entire production process end-to-end.

25 years of experience lead to MOM

iTAC Software AG is a global IT and software company with a 25-year history and has developed from a traceability expert for discrete production processes to a global MOM player for a wide range of industries. Martin Heinz says: " For many years, we have been solving classical requirements such as traceability and production management in the conventional MES, but today it is also important to link production processes and to digitalize them in an agile manner. With the MOM, we have created a holistic platform for this. The functionalities for traceability, production planning or control are still essential, but are extended by new applications with AI and low-code applications, among others, and form a flexible, yet highly standardized system that is also fully scalable and easy to roll out due to the template characteristics."