Bridging ERP and IoT: Why Integration is the Future of Smart Manufacturing

Smart ManufacturingIndustry 4.0Intelligent MES & Machine Monitoring PlatformMachine MonitoringManufacturing Operations Management (MOM)Production Monitoring & AnalyticsProduction Efficiency & Bottleneck EliminationJob Tracking & Scheduling IntelligenceProduction Analytics & ReportingIndustrial IoT Platform & Cloud SolutionsCustomer & Industry Solutions

Nov 19

Written By Alari Valter

Connect machines, operators, and ERP systems to turn fragmented signals into real-time, actionable insights.

Manufacturing is entering a precision era. Output and unit cost still matter, but the new competitive edge is how fast you can sense, decide, and act. GlobalReader links the shopfloor to your ERP backbone so that machine signals, operator actions, and order progress flow automatically — without manual retyping or lag. The result is a single operational truth for planning, costing, and continuous improvement.

Below, we outline the building blocks of a connected factory — and how GlobalReader’s integrations make them practical to deploy, scale, and govern.

What Is ERP Integration and Why It Matters for Manufacturers

ERP integration means connecting your enterprise resource planning software to shopfloor IoT systems so production orders, materials, and feedback move automatically in both directions. With ERP integration, planners see live progress, operators get the right instructions, and finance trusts the data.

From Data Islands to a Connected Factory

Most factories still run on a patchwork of paper travelers, Excel files, and isolated systems. These data islands create latency and blind spots: orders start without the latest routing, small stoppages are invisible, and costing relies on estimates.

By streaming IoT data and operator inputs straight into ERP, GlobalReader replaces assumptions with verifiable telemetry: actual run hours, real good/output quantities, scrap reasons, changeover time, and downtime classification — all tied to the correct work order.

Our core ERP integrations sync orders, products, and materials into GlobalReader and return shopfloor feedback to the source system. This keeps planning and execution aligned minute‑by‑minute and prevents master data drift.

ERP Integration Examples: How Manufacturers Connect Systems in Practice

Below are real examples of ERP integrations supported by GlobalReader. Each example shows how production orders flow from ERP to the shopfloor and how real-time feedback flows back to ERP.

Bridging ERP and IoT: Why Integration is the Future of Smart Manufacturing | GlobalReader

Microsoft Dynamics 365 Business Central (BC)

Imports production orders and products, and returns real-time shopfloor feedback.

Microsoft Dynamics 365 Finance & Operations (FO)

Integrates production and material data for seamless visibility between factory and finance.

Microsoft Dynamics NAV

Imports production orders and materials, and sends live feedback back to NAV.

Microsoft Dynamics AX

Supports real-time feedback from production and order synchronization.

MRPEasy

Imports production orders and sends shopfloor feedback back to MRPEasy.

Monitor G5

Exchanges production orders and material data in real time with shopfloor feedback.

Eziil

Sends production information to GlobalReader for improved analytics and performance tracking.

Noom

Imports production orders into GlobalReader and returns shopfloor feedback back to Noom.

Directo

Imports production orders and materials; sends shopfloor feedback back to Directo.

Paperless, Frictionless Execution

Paper-based travelers introduce delay and transcription errors. GlobalReader replaces them with digital work instructions, barcode/QR scanning, and automatic progress capture from machines and terminals. Operators start/stop jobs, report scrap and downtime reasons, and attach photos or notes right at the station. Data is validated at the source — minimizing rework later in ERP.

Beyond core ERP, we connect operations and compliance tools to extend this paperless flow:

Alldevice — send device and service task information from GlobalReader, keeping maintenance and production on the same page.

VITS — validate training and certifications before a job can start, enforcing safety and compliance rules without slowing production.

Innerrange — import operator worktime to align human presence with machine utilization and shift reporting.

Net effect: shorter handovers, fewer manual corrections, and a provable reduction in paper, printer time, and clerical hours.

Measuring What Matters: Availability, Performance, Quality, Cost

Improvement starts with measurement. GlobalReader computes the building blocks of OEE continuously and ties them to the correct order, machine, and shift:

Availability — how much of planned time the asset is truly productive; microstops and idling are captured, not averaged away.

Performance — cycle times and throughput versus plan, highlighting bottlenecks and pacing loss in real time.

Quality — good units vs. scrap with reason codes, making chronic causes visible across shifts and products.

True product cost — based on measured machine and labor hours plus actual materials, not estimates.

For extended analytics, many teams pair GlobalReader with familiar tools:

Maintenance, Reinvented

Fixed calendar maintenance schedules either waste service life or miss early warning signs. GlobalReader enables work‑hour‑based and condition‑aware maintenance by feeding actual run hours and downtime reasons into your maintenance flow. Trigger service at the practical moment, sequence jobs to reduce changeovers, and align spare parts with realistic consumption.

With Innerrange (operator time) and Alldevice (service actions and history), the loop is closed: you can audit whether maintenance happened, how long it took, and what effect it had on future performance.

Fewer unplanned stoppages and better MTBF/MTTR.

More predictable maintenance cost profiles.

Clear proof of compliance for audits and customers.

Business Impact You Can Quantify

IoT–ERP integration with GlobalReader is not an IT experiment — it is an operational model change that shows up in the P&L and on-time delivery metrics. Typical outcomes include:

+5–15% availability by exposing microstops and enforcing start/stop discipline.

–30–60% manual reporting time by eliminating duplicate entry and end-of-shift spreadsheets.

More accurate standard costs feeding pricing, quoting, and profitability analysis.

Higher employee focus — operators make, planners plan, analysts analyze.

Sustainability gains via less paper, fewer scrap loops, and optimized energy/time-on-machine.

Because the data is measured, not guessed, improvements are defensible in audits and repeatable across plants.

Bridging ERP and IoT: Why Integration is the Future of Smart Manufacturing