Case Study: Blum’s Full Vertical Integration with SAP & a Digital Twin
A production line restructure needed more than just a tech update. It needed a complete rethink. Orise Digital delivered.
#situation
The Situation: Scaling Up Without Slowing Down
Blum GmbH, an Austrian furniture manufacturer with a global reputation for precision and quality, was in the middle of a major Industry 4.0 initiative. The goal was ambitious: to fully vertically integrate production in their new factory by connecting every layer of the operation, from individual machines to SAP, in an effort to make manufacturing efficient, transparent, and agile.
Introducing a new machine into this environment was the critical test. Done right, it would unlock a new era of smart production. Done wrong, it would create costly disruptions, errors, and delays.
The Challenge: Manual Processes Created Unaffordable Risk
The challenge wasn’t just technical. It was operational.
From the outset, Blum understood that if production data were to move between systems manually, it would create a potential failure point. Workers would need to interpret instructions, enter data by hand, and navigate a workflow riddled with discontinuities — gaps where information moved between digital and analog formats.
Specifically, Blum wanted to ensure that their new production facility:
- Eliminated manual data entry between the machine and SAP
- Transferred production orders and parameters automatically, without human intervention
- Optimized material provision so workers spent less time searching and more time producing
- Commissioned the new machine as smoothly as possible with minimal risk to live operations
Without solving these challenges, scaling production would mean scaling errors. That wasn’t an option.
#solution
The Orise Solution: A Networked, Transparent, and Agile Factory Working with Orise Digital, Blum implemented a solution built for the realities of modern manufacturing.
The results speak for themselves.
By fully integrating production directly with SAP, Blum and Orise Digital eliminated manual data entry and streamlined material flows using guided pick-to-light systems. To ensure a flawless rollout, we deployed a digital twin to simulate and stress-test processes before live production ever began. The full case study below shows how this agile setup eliminated commissioning risks and optimized output from day one, including:
- Complete vertical integration from shop floor machine to ERP
- Automated real-time data feedback with zero manual reporting
- Error-free material provision through guided pick/drop-to-light systems
- Faster, lower-risk commissioning through virtual testing with the digital twin
- Full management visibility with real-time production transparency
- Higher quality, flexibility, and traceability across the entire operation
#download
See Exactly How it Was Done
The full case study breaks down the technical architecture, implementation approach, and the specific role Orise Digital’s Manufacturing Manager played in making this transformation possible. If you’re responsible for production efficiency, ERP integration, or digital transformation in your organization, the practical insights could help unlock the full potential of your plant.