DFD — Shop-Floor MES
Discrete assembly plant from ERP order release to goods movement, laid out over Purdue levels 4, 3 and 2 so the 8 enterprise-to-plant hops a segmentation review has to justify are the ones the findings strip names.
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title "Discrete assembly — MES level 1"
level 1
entity "ERP (SAP)"
entity "Supplier portal"
entity "PLC line controller"
entity "Operator terminal"
process 1 "Release work order"
process 2 "Dispatch to station"
process 3 "Record production count"
process 4 "Log defect and scrap"
process 5 "Post goods movement"
process 6 "Receive material lot"
store D1 "Work orders"
store D2 "Station schedule"
store D3 "Production counts"
store D4 "Defect register"
store D5 "Material lots"
boundary "Enterprise IT (Purdue L4)" { "ERP (SAP)", "Supplier portal", 1, 5, D1 }
boundary "Manufacturing ops (Purdue L3)" { 2, 3, 4, 6, D2, D3, D4, D5 }
boundary "Cell control (Purdue L2)" { "PLC line controller", "Operator terminal" }
"ERP (SAP)" -> 1 : "planned order 12 000/wk"
1 -> D1 : "released order"
D1 -> 2 : "open operations"
2 -> D2 : "station sequence"
2 -> "Operator terminal" : "job card"
D2 -> 3 : "planned takt 41 s"
"Operator terminal" -> 3 : "good count"
"PLC line controller" -> 3 : "cycle counter (OPC UA)"
D5 -> 3 : "lot genealogy"
3 -> D3 : "count per shift"
"Operator terminal" -> 4 : "defect code"
4 -> D4 : "scrap record"
D3 -> 5 : "confirmed quantity"
D4 -> 5 : "scrap quantity"
5 -> "ERP (SAP)" : "movement 261 / 531"
"Supplier portal" -> 6 : "ASN + certificate"
6 -> D5 : "lot + expiry"