Article

Intelligent ERP Automation: Connecting the Factory Floor and Cloud with Low-Code

In modern manufacturing, integrating real-time factory floor data with enterprise systems is essential to optimize efficiency and decision-making. Intelligent ERP automation, powered by low-code platforms like Crosser, enables seamless connectivity between operational technology (OT) and business applications. By automating data flows, enhancing analytics, and reducing manual intervention, organizations can achieve greater agility and resilience.

This article explores key insights from real life projects, covering practical use cases, integration strategies, and the benefits of low-code automation in industrial environments.

Key Use Cases for ERP Automation in Manufacturing.

1. Connecting Factory Floor Data to ERP Systems

Manufacturers continue their digital transformation journey, investing in core technologies like cloud, AI, 5G, and XR to improve operational efficiency and innovation. Key areas of investment include smart operations systems that connect the enterprise with the shop floor, the Unified Namespace for streamlined data integration, and XR technologies for training and workforce support.

Use Case Example: A manufacturer uses a low-code platform to connect the production machines with their ERP system. The system automatically updates inventory and production schedules based on real-time machine data, allowing the business to adjust production plans dynamically and optimize resource allocation.

2. Condition-Based Work Orders

A common use case involves analyzing factory data before it’s sent to the ERP system. This involves integrating a validation module that checks various conditions in real-time. Data can be processed to verify if values fall within predefined thresholds or if specific events have occurred within a time frame. When a criteria is met, the ERP system can automatically generate a work order, ensuring proactive maintenance and enhanced workflow automation.

Use Case Example: A production line with multiple machines uses real-time sensor data to monitor temperature, pressure, and speed. If a sensor detects a machine running outside optimal parameters, an automatic work order for maintenance is triggered within the ERP system, preventing unplanned downtime and improving efficiency.

3. Deriving Insights Through Machine Learning

In addition to raw data transmission, businesses can use machine learning models to derive actionable insights from factory data before it’s integrated into the ERP system. For instance, machine learning can predict maintenance schedules or calculate key performance indicators (KPIs) based on real-time data. This approach reduces the processing load on the ERP system and allows for deeper, large-scale data analysis at the point of origin.

Use Case Example: A factory deploys machine learning algorithms that analyze time-series data from its machines. The model predicts when a specific machine is likely to fail and triggers a maintenance order through the ERP system, optimizing both maintenance schedules and production uptime.

4. Expanding ERP Connectivity

Multi-Output Automation
Beyond connecting data from the factory floor to the ERP system, automation can trigger multiple actions based on predefined events. These events might require immediate attention, such as notifications or alerts. For instance, a critical machine failure could trigger an immediate text message to engineers, ensuring timely intervention alongside ERP-driven work orders.
Use Case Example: In a factory where machines are monitored in real-time, any detected failure immediately triggers an alert to a maintenance team’s mobile device. This ensures quick intervention and reduces downtime, while the ERP system manages the maintenance workflow.
Bidirectional ERP Communication
Automation isn't just about sending data to the ERP system; it also involves sending data from the ERP system back to the factory floor. An example is ERP-driven pallet labeling.
Use Case Example: An ERP system retrieves order details when a barcode scanner on the production line identifies new pallets. The system ensures that the correct label is printed at the right moment, automatically updating the pallet status and reducing manual intervention.

5. Cloud and On-Premise ERP Integrations

For businesses operating a mix of cloud and on-premise ERP systems, ensuring seamless communication between these platforms is essential. Low-code automation can provide secure, event-driven communication, allowing data to flow freely between systems.

Salesforce to SAP Integration
A common scenario is the integration of a cloud-based CRM like Salesforce with an on-premise ERP system such as SAP. When a new order is created in Salesforce, data is automatically pushed to the SAP ERP system, without exposing internal systems to the internet.
Use Case Example: A company using Salesforce for order management automatically synchronizes sales data with their on-premise SAP ERP system, ensuring seamless order processing and reducing manual data entry errors.
Secure Cloud-to-On-Premise Data Exchange
Some companies may prefer a secure way to connect cloud services to on-premise ERP systems without direct inbound connections. Low-code automation can facilitate this integration via secure communication channels like MQTT brokers.
Use Case Example: A company that operates both cloud-based inventory management and an on-premise ERP system uses MQTT brokers in the cloud to securely transmit inventory updates from the cloud to the ERP system without any inbound connections, ensuring data consistency and security.

Advantages of Intelligent ERP Automation

Faster Time-to-Value: Low-code platforms enable rapid deployment of automation workflows, reducing the time and cost of traditional software development.
Reduced Manual Effort: Automating repetitive data entry and reporting tasks frees up employees to focus on higher-value activities.
Improved Decision-Making: Real-time data synchronization ensures that business leaders have up-to-date insights for strategic planning.
Enhanced Scalability: Whether operating on-premise, in the cloud, or at the edge, automation solutions can scale alongside business growth.
Stronger Compliance and Traceability: Automated documentation and audit trails help meet regulatory requirements with minimal manual effort.

Interested in Learning More About ERP Automation in Manufacturing?

As digital transformation continues to reshape the manufacturing industry, intelligent ERP automation, powered by low-code platforms, is becoming essential for businesses striving to stay competitive. By leveraging seamless integrations, companies can enhance operational efficiency, reduce costs, and make more informed, data-driven decisions.

To dive deeper into these concepts and see real-world examples of automation in action, watch the full webinar video.

12 Mar 2025

About the author

Goran Appelquist (Ph.D) | CTO

Göran has 20 years experience in leading technology teams. He’s the lead architect of our end-to-end solution and is extremely focused in securing the lowest possible Total Cost of Ownership for our customers.

"Hidden Lifecycle (employee) cost can account for 5-10 times the purchase price of software. Our goal is to offer a solution that automates and removes most of the tasks that is costly over the lifecycle.

My career started in the academic world where I got a PhD in physics by researching large scale data acquisition systems for physics experiments, such as the LHC at CERN. After leaving academia I have been working in several tech startups in different management positions over the last 20 years.

In most of these positions I have stood with one foot in the R&D team and another in the product/business teams. My passion is learning new technologies, use it to develop innovative products and explain the solutions to end users, technical or non-technical."