How integrated MOM and automation accelerate digital transformation for CPG manufacturers

Siemens’ integrated MOM and automation solution is optimizing the path to digital  transformation

Manufacturing: Accelerating  digitalization from ERP to automation

CPG manufacturers clearly understand the value of both manufacturing operations management (MOM) solutions and process automation, as well as the integration of those solutions to complete digitalization from ERP to the shop floor. When these systems are seamlessly integrated, the manufacturing enterprise becomes efficient and agile, while producing high quality batches every time.

The integration creates fully digital capabilities that include:

• Material traceability and genealogy
• Equipment initialization, configuration updates, availability and allocation based on work order parameters
• Resource optimization through advanced scheduling
• Orchestration automation with MES actions and events

Together, these capabilities transform operational excellence and create a digital thread that supports a connected quality process, helps prevent errors and supports compliance.

As manufacturers approach their digital transformation roadmap, they typically approach MOM and process automation in silos, defining different projects and teams for their design and implementation. The potential of these solutions is diminished with this siloed approach, not only from an architectural and integration standpoint, but from the redundant work and associated costs of separate teams, and the subsequent integration work required.

Siemens has been working with CPG manufacturers for decades, across all segments of the industry. We have seen the positive impact  of integrated MOM and automation firsthand, reducing complexity, accelerating time to market, generating tremendous operations and strategic efficiencies. For that reason, we have invested in pre-configuring the integration to make our customers’ journeys even faster, breaking down the barriers across these functions.

Just as we previously integrated our MES solution with Simatic Batch for the chemicals industry, CPG manufacturers can now benefit from our integrated solution approach. Our MES integrations with SISTAR and BRAUMAT process control systems support food and beverage manufacturers, including food processing and brewing customers. We are applying this experience to deliver out-of-the-box integrations for the CPG industry.

Now, CPG manufacturers can approach digital transformation as a single, phased project, from process automation to MOM to ERP. With integration capabilities and tools available through the MES platform, implementation can be streamlined into one integrated solution. When working with Siemens automation, this integration is preconfigured to help reduce complexity and support a more efficient implementation.

Beyond the efficiency impact, customers can create a more strategic roadmap, with design done in parallel to support one unified vision and optimize resources and timelines for implementation.

Integrated MOM and automation enable the golden batch standard in CPG

“Golden Batch” is a term used in the chemicals industry, referring to the production batch that meets all of the requirements and is considered the best one ever produced. It is the “gold standard” of batches. The same concept applies to CPG: creating a fully digital manufacturing environment that targets better batch outcomes every time while using AI and ML to analyze connected production and quality data, identify patterns and support continuous improvement.

When automation and MOM are integrated, we can look back and see what line, what equipment, what process parameters were recorded, what raw material and semi-finished goods were used when the perfect batch was produced. Likewise, we can understand what prevented us from achieving the perfect batch. What were the differences?

Let’s look at how these systems work in concert to consistently produce the perfect batch. First, the formulated product development creates the digital twin of the formula and the definition of various quality parameters. When we are ready to move the digital twin to production, we share the formula and recipe with the MES solution, which enforces flawless execution of that recipe on the shop floor, according to the schedule generated by the advanced planning and scheduling (APS) system. That solution allows us to schedule all the different work orders from the ERP efficiently for manufacturing.

During manufacturing, the laboratory information management system (LIMS) seamlessly integrates with manufacturing execution. Triggered by the inspection plans, the MES will initiate taking samples, which are transferred to the lab for analysis. If the analysis is acceptable according to the quality parameters, the LIMS issues the batch release decision back to the MES. So, we make sure we only continue production with good quality batches.

We can see that quality is built in, supporting true closed-loop quality from incoming materials through finished batch release. Quality sampling can begin when raw materials are delivered, helping verify that only approved materials enter production. During production, quality checks are triggered by inspection plans, verified through LIMS and connected back to MES for batch release decisions. Contextualizing quality information with process information enables process parameters to be linked to batch quality, so teams can understand why one batch differs from another and what may have prevented them from reaching the perfect batch goal. This creates a continuous improvement loop that helps teams move closer to the perfect batch every time.

We also see efficiency built in with scheduling and resource orchestration. Understanding equipment capabilities, availability and configuration allows teams to schedule batches on the right equipment, as well as plan maintenance during optimal time windows, all done systematically.

AI-powered closed-loop manufacturing drives continuous quality improvement 

Closed-loop manufacturing helps CPG teams move closer to the Golden Batch by connecting design intent, production execution, quality verification and continuous improvement. Once recipe intent, execution data, quality results, equipment status and process context are connected, teams can compare target conditions with actual performance and better understand what influenced each batch outcome. 

AI can take this a step further when production and quality data is connected and contextualized. Rather than looking at each batch in isolation, teams can use AI to help identify patterns across batches, surface early signals of process drift and understand which process conditions are most closely associated with better batch outcomes. 

The purpose is not to replace process expertise. It is to give process engineers, plant managers, plant orchestrators and production line managers earlier signals from the data they already create. With more context around production and quality data, teams can better anticipate process drift, act before issues lead to scrap, efficiency loss or rework, verify decisions with more confidence and keep moving closer to the Golden Batch. 

Siemens’ pre-configured integration reduces implementation time and cost

Siemens is making this a reality for our customers today. Through our out-of-the-box integrated solution, we have woven the digital thread across formulated product design, LIMS, MES, APS, Manufacturing Intelligence and integration to automation, enriched with AI to help teams analyze connected production and quality data. CPG manufacturers now have a “one-stop shop” for fully digital manufacturing from ERP to automation. 

Our pre-configured system integrations accelerate digital transformation for CPG manufacturing. We have certified protocols that ensure integrations are valid and complete. Our solution includes out-of-the-box features sets such as libraries, templates and guidelines, as well as project implementation documents, that give design and implementation teams a jump start on a successful transformation. 

For global manufacturers, we offer multi-plant support through a regional hub that serves multiple local sites while respecting data segregation between plants. This approach helps transfer correct, current information to each shop floor and enables teams to reuse configuration data from an initial deployment to bring additional plants online more efficiently. 

We continue to anticipate market and technology trends that help CPG manufacturers use production and quality data more effectively. Today, connected production data can be contextualized through solutions such as Insights Hub integrated with MES, giving teams a stronger foundation for analysis and continuous improvement. 

As Siemens expands its industrial AI capabilities, including capabilities from Altair RapidMiner, the next step is an AI Fabric layer that can connect data, models, automation and governance across systems such as automation, MES and ERP. This helps create the context AI needs to support more useful analysis, identify patterns across batches and uncover opportunities to improve quality, efficiency and consistency over time. 

Our modularized approach to software expansion allows our customers to continue to build their digital infrastructure with new capabilities, however and wherever they want to deploy, whether it be on premises, in the cloud, or a hybrid approach. 

We are excited to partner with our CPG manufacturing customers to help them build quality and compliance into every batch. With Opcenter Execution as part of our integrated MOM approach, manufacturers can connect production execution with process control, quality verification and automation in a more unified way. Our pre-packaged integration between manufacturing operations and process control helps reduce the cost and risk of digital transformation initiatives, while accelerating the journey toward higher efficiency, quality and time to market. In that kind of environment, innovation is fostered and new possibilities are brought to life. 

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Frequently asked questions: Integrated MOM and automation for CPG

1. What is the main challenge CPG manufacturers face with digital transformation? 

CPG manufacturers typically approach manufacturing operations management (MOM) and process automation in silos, defining different projects and teams for design and implementation. This siloed approach diminishes the potential of these solutions through redundant work, higher costs, and complex integration requirements. 

2. What is Manufacturing Operations Management (MOM)? 

Manufacturing Operations Management (MOM) is a comprehensive solution that manages and optimizes manufacturing processes from order release to finished goods. It includes capabilities like advanced planning and scheduling (APS), manufacturing execution systems (MES), laboratory information management systems (LIMS), and manufacturing intelligence.

3. What is the “Golden Batch” concept? 

The “Golden Batch” refers to the production batch that meets all quality requirements and is considered the best one ever produced. It serves as the quality benchmark. In CPG manufacturing, integrated MOM and automation systems work together to consistently produce this perfect batch by connecting design intent, execution, quality verification, and continuous improvement. 

4. How does Siemens’ integrated approach differ from traditional implementations? 

Siemens provides pre-configured, out-of-the-box integration between MOM and process automation systems (including SISTAR, BRAUMAT, and Simatic Batch). This allows CPG manufacturers to approach digital transformation as a single, phased project rather than separate initiatives, reducing implementation time, costs, and integration complexity. 

5. What are the key benefits of integrated MOM and automation?

Integrated MOM and automation deliver:

• Material traceability and genealogy across the production process
• Equipment optimization through advanced scheduling and resource allocation
• Closed-loop quality that prevents errors and ensures compliance
• Reduced implementation costs by eliminating redundant work
• Faster time to market through streamlined, unified implementation
• Embedded AI, machine learning and low-code capabilities that help teams improve processes, extend solutions more easily and optimize user experiences

6. How does closed-loop manufacturing work with integrated systems?

Closed-loop manufacturing connects product development, recipe management, production execution, quality verification and continuous improvement. The MES enforces recipe execution according to the production schedule, while LIMS integrates with manufacturing execution to trigger sample collection, perform analysis and issue batch release decisions back to MES. This helps ensure only quality-approved batches continue through production.

7. What role does AI play in achieving the Golden Batch?

AI supports predictive quality by analyzing connected production and quality data to identify patterns across batches, surface early signals of process drift and understand which process conditions are most closely associated with better batch outcomes. This helps process engineers, plant managers, plant orchestrators and production line managers anticipate issues before they lead to scrap, efficiency loss or rework, verify decisions with more confidence and keep moving closer to the Golden Batch.

8. Can Siemens’ solution scale for global manufacturers?

Yes. Siemens offers multi-plant support through a regional hub architecture that can serve multiple local sites while respecting data segregation between plants. This approach helps transfer correct, current information to each shop floor while allowing manufacturers to reuse configuration data from an initial plant deployment to bring additional sites online more efficiently. The modularized approach allows deployment on premises, in the cloud or in a hybrid configuration.

9. What industries benefit from Siemens’ integrated MOM and automation solution?

The solution is designed specifically for Consumer Packaged Goods (CPG) manufacturers, including:

• Food processing
• Beverage and brewing
• Personal care products
• Household goods
• Any CPG segment requiring batch production with strict quality controls

10. How does this integration accelerate digital transformation timelines?

By providing pre-configured system integrations, certified protocols, out-of-the-box feature sets (libraries, templates, guidelines), and project implementation documents, Siemens eliminates redundant design work and reduces integration complexity. Teams can work in parallel with a unified vision, optimizing resources and implementation timelines.