BASF

BASF, one of the world's largest chemical companies, faced significant operational complexity in producing Xemium®, its environmentally safe fungicide supporting sustainable high-yield farming. The Xemium line runs 24 hours a day, 365 days a year, combining continuous and batch processes with laboratory quality control and end-of-line packaging — a configuration that demands precise coordination across every production stage. A critical gap between ERP and SCADA systems left production visibility fragmented, forcing operators to rely on manual data collection and paperwork that consumed roughly five working days per month. Without a unified digital layer, production transparency was limited and batch cycle times could not be systematically optimized, putting both throughput and timely customer delivery at risk.

BASF partnered with Siemens to implement Opcenter Execution Process, a Manufacturing Execution System (MES) designed for continuous and hybrid process environments. The platform served as the foundation for vertical process integration, closing the data gap between BASF's ERP and SCADA layers by establishing a complete digital thread across the Xemium production line. Quality control was embedded directly within the digitalized workflow rather than treated as a downstream check, enabling inline monitoring throughout each batch. Handheld scanners replaced manual data entry at the operations level, feeding real-time production data into the system automatically. This end-to-end integration gave production teams a single, accurate view of the manufacturing process — from raw material input through packaging — enabling data-driven decisions and consistent batch execution at the pace required by a 24/7 operation.

The digital thread established through Opcenter delivered measurable improvements across both throughput and administrative overhead:

• 5–10% reduction in batch production time — a meaningful gain in a 24/7 continuous operation where each percentage point compounds across hundreds of annual cycles
• 5 days of manual paperwork eliminated per month — achieved through automated production data capture, freeing operators to focus on process oversight rather than documentation
• Improved on-time delivery — fungicide supply reached customers on a more reliable schedule, directly supporting growers dependent on crop protection timing

Qualitatively, integrating quality control into the digitalized process rather than at end-of-line reduced the risk of batch deviations propagating undetected, improving overall production consistency.

• Closing the ERP-to-SCADA gap is often the highest-leverage integration point in chemical manufacturing — without it, production data remains siloed and optimization is guesswork
• Embedding quality control within the digital workflow, rather than after production, catches deviations earlier and reduces batch rejection risk
• Automated data capture at the operator level (e.g., handheld scanners) is a practical first step that delivers immediate ROI through paperwork reduction before more complex AI layers are introduced
• In 24/7 continuous operations, even modest percentage improvements in batch cycle time compound significantly over an annual production calendar
• A complete digital thread must span the full process — from raw material to packaging — partial integration leaves critical blind spots