Integration of MES, SAP, And PI Historian Platforms for Real-Time Industrial Asset Performance Management

Abstract

This study examined the integration of Manufacturing Execution Systems, SAP enterprise applications, and PI Historian platforms for real-time industrial asset performance management. A multisite, retrospective longitudinal, quasi-experimental quantitative design was employed across 18 asset-intensive industrial facilities. The study covered 48 consecutive months, comprising 24 preintegration and 24 postintegration months. Propensity-score matching produced 600 comparable assets, divided equally between high-integration and partial- or fragmented-integration conditions. The final dataset contained 28,224 asset-month observations, 4,286 verified failures, 52,614 condition alerts, 8,932 maintenance notifications, and 8,147 work orders. Data were analyzed using mixed-effects regression, negative-binomial modeling, difference-in-differences estimation, interrupted time-series analysis, survival analysis, recurrent-event modeling, mediation, moderation, and sensitivity testing. High-integration facilities achieved 92.4% interface automation, 99.3% transaction success, 98.7% asset-mapping accuracy, 98.8% data completeness, and 94.1% event traceability. After adjustment for asset, operational, maintenance, facility, and baseline characteristics, high-integration assets recorded a 32% lower failure rate, IRR = 0.68, 95% CI [0.61, 0.75], p < .001, and 51% lower repeated-failure odds, OR = 0.49, 95% CI [0.39, 0.62], p < .001. Mean time between failures increased by 2,310 hours, while mean time to repair declined by 3.08 hours. Availability increased by 2.18 percentage points, overall equipment effectiveness increased by 4.96 percentage points, and annual unplanned downtime declined by 55.1 hours per asset. Throughput attainment increased by 5.04 percentage points, quality yield increased by 1.36 percentage points, annual maintenance cost decreased by USD 12,600 per asset, and annual production-loss value declined by USD 45,800 per asset. High-integration assets experienced a 44% lower failure hazard and achieved a median failure-free duration of 8,420 hours. Real-time information visibility and maintenance responsiveness mediated 53.4% of the integration–performance relationship. The findings established that coordinated MES–SAP–PI Historian integration was associated with improved reliability, maintainability, availability, production continuity, quality performance, and economic control.