MACO Teclink: Digital Transformation of Manufacturing
Learn how MACO is digitizing production and ensuring true data security through the Teclink project, in collaboration with meshmakers and COPA-DATA..
In the modern manufacturing industry, data is the new gold. But as with any raw material, it is the processing that determines its true value. Raw data alone is often inaccurate, incomplete, and difficult to interpret. This is exactly where Mayer & Co Beschläge GmbH (MACO) comes in.
With its ambitious digitalization project “Teclink,” the leading manufacturer of window and door hardware is moving away from outdated Excel spreadsheets and “gut feelings” as the basis for decision-making. Instead, the company is embracing a fully connected, data-driven future.
In collaboration with its technology partners meshmakers and COPA-DATA, MACO has created an infrastructure that not only collects data but also transforms it into actionable insights.
The challenge: Many machines, little insight
Before Teclink was launched, MACO faced a challenge that is likely familiar to many manufacturing companies: a vast machine park with over 1,000 machines, but very little transparency.
The system environment was heterogeneous. Different manufacturers, varying model years, and a multitude of protocols made uniform control virtually impossible. Key metrics were often only available after the fact, which made it difficult to take proactive action.
The consequences were palpable:
- No real-time insight into ongoing production.
- High manual effort due to paper-based processes.
- Lack of a comprehensive database for strategic investment decisions.
The goal was clearly defined: to move away from static analytics toward real-time KPIs and company-wide TEEP (Total Equipment Effectiveness and Performance) analytics. And all of this without spending millions on in-house development, but rather through intelligent networking.
The Solution: A Bridge Between OT and IT
To turn this vision into reality, MACO opted for a modular architecture. At its core is the OctoMesh platform from meshmakers, combined with the zenon HMI/SCADA software from COPA-DATA.
OctoMesh: The Data Conductor
OctoMesh serves as a central platform for data integration, transformation, and distribution. It seamlessly connects the shop floor (OT) with the IT environment (SAP, Power BI). This enables a closed-loop system in which SAP and production collaborate based on data.
Zenon: The Eye in the Machine
zenon provides direct machine connectivity and visualization at the production level. The software enables direct access to machine data and provides live status updates that immediately highlight any issues in production.
The app for machine operators
A highlight of the project is the involvement of on-site employees. Meshmakers developed a special app for machine operators that digitizes and simplifies their daily work:
- Easy login: Operators log in directly at the machine using a tablet.
- Order Management: Production orders can be selected and initiated digitally.
- Quality assurance: Test results and feedback are recorded directly in the app—paperless and in real time.
Why Validation Is the Key to Success
One aspect of digitalization projects that is often underestimated is the quality of the raw data. Data collected automatically is not always perfect. Sensors can fail, and transmissions can be incomplete. If this data were used for strategic decisions without being verified, the consequences could be disastrous.
That is why the project team incorporated a crucial intermediate step: validation by data product owners.
Productive use and true digital data security are only possible once the data has been validated. Data Product Owners check the automatically captured values for plausibility and gaps. Only after this cleansing process is the data released for company-wide strategies and reporting.
The result is a “single source of truth”—a single, reliable data source that everyone, from machine operators to management, can rely on.
The benefits: More than just colorful dashboards
With Teclink, MACO has not only introduced new software, but has also transformed the way the company operates.
- Real-time transparency: Instead of looking back at the past week, teams now work with live data. Bottlenecks are identified and resolved immediately.
- Paperless processes: Using the app speeds up workflows and drastically reduces the likelihood of errors.
- Informed decisions: Investments and strategic directions are now based on valid facts, not estimates.
- Scalability: The standardized IT/OT architecture can be easily rolled out to additional plants.
A Look into the Future
Teclink is just the beginning of MACO’s digital journey. The foundation that has been laid now enables the integration of additional areas such as warehousing and logistics. In addition, the team is already working on solutions for automated ESG reporting to analyze and optimize energy consumption based on data.
As Reinhard Mayr, co-founder of meshmakers, aptly puts it: “TecLink is a prime example of how OT reality can be seamlessly integrated with modern IT architecture. With OctoMesh, we were able to create not just interfaces, but real added value—from the shop floor all the way up to management reporting.”
MACO impressively demonstrates how traditional manufacturing and cutting-edge digital technology can work hand in hand to secure competitive advantages and enable sustainable growth.
Would you like to learn more about how you can turn your production data into valuable insights? Contact us for a no-obligation consultation.
