AESSEAL, a subsidiary of AES Engineering Ltd, is renowned for its innovative engineering of products and systems designed to prevent environmental leaks from pumps and rotating equipment. Their offerings not only enhance equipment reliability but also reduce maintenance costs. With a global presence spanning 235 locations across 104 countries, AESSEAL’s expanding operations necessitated a modern technology stack that could seamlessly integrate with their legacy systems. Faced with the risk of falling behind their own progress, AESSEAL turned to the Mendix low-code development platform, an integration they discovered through their long-standing relationship with Siemens as Teamcenter users.

In 2022, AESSEAL’s IT team embarked on a proof of concept (POC) using Mendix to modernize a legacy shop floor solution. This initiative aimed to test the platform’s integration capabilities with essential engineering systems. The success of this pilot project has set the stage for AESSEAL to standardize their low-code development approach, leveraging Mendix to maintain a clean core while co-developing with expert partners to expand their team.

Integration Challenges Stifling Innovation

Stuart Welsh, IT Director at AESSEAL, highlighted the significant challenges posed by siloed legacy manufacturing systems. The technical debt accumulated over the years had hindered the IT team’s ability to deliver innovative solutions.

“From an IT perspective, our challenges are integration, integration, and integration,” Welsh stated. “SAP has transformed our business, enabling us to navigate through COVID and remote work effectively, but integrating it with other systems, including Teamcenter, is a monumental task.”

Balancing the demands for new solutions with the need to adhere to SAP and Siemens guidelines to keep the core systems clean has been a persistent challenge. Welsh’s team, already stretched thin by constant upgrades in Windows and Oracle, found it difficult to address the numerous tasks on their agenda. The need for a solution became evident when Welsh connected with other organizations facing similar challenges at the Mendix UK Manufacturing Forum in 2022. This encounter spurred AESSEAL to move forward with a Mendix POC in October 2022.

A POC That Makes a Difference

AESSEAL’s IT team understood that the POC needed to demonstrate critical business functionality and integration capabilities. The chosen project aimed to update a key shop floor software system reliant on outdated technology, which was limited to specific Windows versions and connected to SAP, Teamcenter, and their manufacturing execution systems (MES).

“We chose Live Lists for our proof of concept because it addressed a clear business need and allowed us to test SAP integration, Teamcenter integration, and user permission controls,” Welsh explained.

With a team consisting of an SAP architect and a Live Lists product owner, AESSEAL quickly developed an application with an improved user interface that:

• Integrated production orders and stock plans from SAP.
• Allowed operators to manage job sequencing based on material supply and demand.
• Alerted operators when machines required cleaning or maintenance.
• Displayed 3D JT files from Teamcenter or 2D drawings.

“This project enabled operators to send CAM programs directly to machine controllers from Live Lists,” Welsh said. “Despite some challenges, the project was a success, and we love the results.”

Following Mendix’s and expert partner Roboyo’s advice, AESSEAL released a minimum viable product (MVP) to a core set of users, collecting feedback to inform their approach to scaling the application and enhancing their Mendix competency.

Building a Scalable Foundation

Buoyed by the success of the Live Lists project, AESSEAL began developing starter applications to create a unified branding experience across user interfaces and enrich user permissions with advanced authentication and application access controls.

“We used the SAP connector for the first time and integrated user authentication, background applications for SAP communication, and a similar approach with Teamcenter,” Welsh noted. “These foundational elements are complete, functional, and ready for our next Mendix applications.”

AESSEAL generated a backlog of features and applications to build with Mendix, starting with enhancements to the Live Lists feature, including user authentication capabilities developed in the starter application.

“Delivering enhancements with low-code was far faster than with legacy tools,” Welsh said. “We’ve also hired a junior developer, a senior team member is starting Mendix certification, and we’re recruiting a tester. We’re growing our internal Mendix team and have taken that initial leap of faith.”

Embracing Innovation

AESSEAL has transitioned from testing low-code concepts to incorporating Mendix into critical business workflows. The enthusiasm for Mendix has spread throughout the organization, leading to a growing backlog of 40 potential applications suited for low-code development.

“We introduced a senior C#, .NET developer to low code, and now 90% of her work is Mendix-based,” Welsh said. “She loves it.”

AESSEAL’s vision for Mendix is clear: if an application or feature cannot be built natively in Teamcenter or SAP, they will turn to Mendix. This approach is crucial as the team has already implemented SAP S/4HANA in 33 countries.

“Based on the success of our proof of concept, we’ve committed to the platform,” Welsh said. “Developing in Mendix is three to four times faster than traditional methods. Our team is convinced of its effectiveness.”

Welsh also shared valuable lessons learned, such as the importance of selecting the right initial project and ensuring adequate support beyond go-live. For organizations starting with low-code, he offers the following advice:

• Get team members involved early: Early involvement fosters ownership and passion for the project.
• Invest in training: An experienced consulting partner can expedite application development and empower your IT team.
• Follow best practices: Adhering to best practices ensures long-term success, despite the temptation to take shortcuts.

The Road Ahead

With Mendix, AESSEAL has bridged the gap between legacy and modern technology, creating a more connected, future-ready engineering environment. The platform has streamlined integration challenges, allowing the team to focus on delivering innovative solutions.

“Mendix helps us deliver faster,” Welsh concluded. “It alleviates many integration headaches, enabling us to concentrate on providing solutions.”

By embracing low-code development with Mendix, AESSEAL is well-positioned to enhance their manufacturing efficiency and continue their legacy of engineering excellence.

Photo by Ricardo Gomez Angel (unsplash.com)