Hofmann Neopac AG’s management decided to introduce an effective MES system for two existing and two new tube production lines in Hungary using a sophisticated OEE and waste-optimised measuring system. Six to eight light sensors were installed along the lines for all four tube production lines. The sensors were connected to Siemens PLC S7-1200 controllers at each production site and then used for monitoring. SAP ERP automatically transfers the order data and required quality assurance data (interval and inspection batch) to the MES system. Any disruptions with a clear cause for the disruption are then recorded on the line using the touch monitor in MES. OEE order KPIs are calculated based on sensor data, the reasons for disruption, etc. The KPIs are simultaneously visualised for large-scale production monitoring. A waste-optimised process improves the discharge rate and thus reduces rejects by four to six per cent.