In industrial systems, existing machines can be securely connected to SAP S/4HANA in real time. This is made possible by an IoT solution that does not require any intervention in machine control systems and is based on standard protocols. It enables real-time integration of production data in SAP – secure, scalable and without duplicate data storage.
The IoT expert and co-developer of this solution is Perinet GmbH, which implements an end-to-end infrastructure from the field level to IT (including the cloud) based on standards. This allows for direct, smart, and secure integration of sensors and actuators with the cloud, the internet, and company IT.
The challenge: Hurdles in the use of data in existing systems
A manufacturing company wanted to make the number of parts produced available directly in SAP S/4HANA – in real time. Access to production data is key to a company’s competitiveness. But that’s not enough – they also need to be systematically integrated into the ERP.
This is often difficult, especially in existing production environments. This is because many machine control systems are not readily accessible. The flow of information between production and management is often interrupted or significantly delayed. There is no consistent data foundation in many cases, even though it would be essential for operational decisions.
This lack of integration leads to an information gap and makes it difficult to evaluate production performance transparently. Management, for example, could only access production metrics with a delay, which unnecessarily extended response times to disruptions or capacity bottlenecks. The company commissioned Perinet and Zentinel NDS to develop a specially tailored IoT solution.
Challenges at a Glance
- Production data is missing from the ERP system.
- Existing machine controls are difficult to access.
- The data foundation is often incomplete and delayed.
- Transparent performance evaluation is difficult.
The solution: IoT integration without interfering with machines
The new system operates without direct intervention in the machine environment and delivers robust and reliable data. For this, IoT devices with an external sensor are used, which can register, for example, every completion signal of a component. The data is temporarily stored locally, and SAP S/4HANA accesses it directly via the SAP Smart Data Access function – without time delays or duplicate data storage. The existing SAP system can therefore be used without modifications.
Technical architecture at a glance
The implemented concept combines Single Pair Ethernet (SPE), a network adapter, an edge server and SAP Smart Data Access.
The ZentNode network adapter is designed for the digitalization of industrial production processes. It captures signals directly from existing or retrofitted sensors in a production system, processes this information locally and securely transmits it via SPE to IT systems. It can be installed on existing machines without modification. In addition, it requires no PLC programming and no complex network configuration.
The ZentEdge server is a robust edge computer that collects, stores, and processes machine data from ZentNode. The data is stored in the SQL database of ZentEdge and made accessible to your existing systems via standard IT protocols. ZentEdge serves as a bridge between operational technology (OT) and information technology (IT), using Single Pair Ethernet (SPE).
Single Pair Ethernet (SPE) handles communication between the individual components. It enables data transmission at 100 Mbps and power supply through a single cable, significantly reducing installation effort. SPE eliminates the need for complex gateways and allows the integration of industrial devices into IT networks using standard protocols such as HTTPS and MQTT, or via a REST API. All data transmission is additionally secured using mTLS certificates.
SAP Smart Data Access (SDA) is a feature of the SAP HANA database for data virtualization. It allows companies to access external data sources from within the SAP system in real time, without having to physically integrate them into the HANA database. This leads to a significant reduction in storage requirements, as no copies of the production data are created. The data also remains consistently up to date.
Simple setup and high reliability
A key feature of the solution is its easy configuration via a browser-based interface. The adapters can also connect to machines with varying cycle times and requirements. Several adapters can be operated in parallel in larger production environments.
Another advantage is the high level of fault tolerance. If the connection to SAP S/4HANA is interrupted, the ZentEdge server temporarily stores the production data locally for SAP. Once the connection is restored, synchronization occurs automatically. This ensures consistent data flow.
The solution is not limited to a single industry. In the chemical sector, for example, mixing quantities and reaction times can be recorded and synchronized with the ERP system. In the food industry, throughput times and quantities can be automatically documented. In medical technology, the integration supports seamless traceability of sensitive manufacturing processes.
The result: Real-time data as a foundation for digitalization
The IoT solution demonstrates that seamless and secure integration of production data into SAP S/4HANA is possible even in existing environments – without interfering with machine control and without extensive adjustments to the existing IT infrastructure. Data virtualization ensures that no data copies are created, but instead enables virtual real-time access. This creates a transparent data foundation for management-level decision-making.
The solution also shows that modern IoT concepts can be combined with existing systems without requiring proprietary structures or complex integration projects. This opens the door to real-time data processing even for small and medium-sized enterprises. The architecture is designed to allow new requirements to be implemented at any time, providing a reliable foundation for further digitalization steps in manufacturing.
Summary of results
- Production data is available in real time in SAP S/4HANA.
- Machines remain unchanged and systems untouched.
- The solution works in heterogeneous environments.
- Operational reliability is ensured through local buffering.
