Manufacturing Execution System (MES)

A Manufacturing Execution System (MES) is a software-based solution designed to monitor and control production processes on the shop floor. It acts as a bridge between enterprise resource planning (ERP) systems and the actual manufacturing operations, providing real-time visibility and control over production activities.

Why Manufacturers Need an MES

Manufacturers need an MES to:

• Optimize Production: By tracking and documenting the transformation of raw materials into finished products, an MES ensures efficient resource allocation, workload balancing, and on-time deliveries.

• Enhance Quality Control: MES systems enforce quality control procedures, monitor metrics, and capture real-time data to ensure compliance and reduce waste.

• Improve Decision-Making: With comprehensive and accurate production data, MES systems empower organizations to continuously improve processes and optimize resource usage.

Build vs. Buy: Why Most Manufacturers Choose to Build

Many manufacturers opt to build their own MES systems rather than buying off-the-shelf solutions due to:

• Customization Needs: Off-the-shelf MES systems may not fully align with specific manufacturing processes and requirements.

• Scalability: Custom-built MES systems can be designed to grow with the business, accommodating future expansions and changes.

• Integration: Building an MES allows for seamless integration with existing systems and processes, ensuring a cohesive and efficient workflow.

Core Capabilities of an MES

An MES should generally have the following core capabilities:

1. Work Order Creation

2. Scheduling

3. Real-time OEE Calculation

4. Downtime Tracking

However, work order creation and scheduling are often handled at the ERP level. Additional capabilities that can be added to an MES include:

1. Recipe Management

2. Digital Quality Inspection Plans

3. Statistical Process Control

4. Statistical Process Analysis

5. ISO 9001 Compliance

6. Digital Work Instructions

7. Bill of Materials

What Manufacturers Must Know Before Building an MES

Before attempting to build an MES, a manufacturer must:

1. Assess Needs and Capabilities: Have a realistic assessment of the long and short-term must-haves and desired capabilities, understand why they cannot use an off-the-shelf solution if one can be found, and have a desired delivery time-frame.

2. Educate the Organization: Ensure that not only individuals but the entire organization is educated about the MES system and its benefits.

3. Acknowledge Knowledge Gaps: Recognize what they know and what they don’t to understand what they are asking for.

4. Be Agile: Conduct realistic assessments regularly and be agile in adapting to changes.

5. Document Progress: As an automation enabler, document the assessments based on the things the manufacturer had requested and show them how much smarter they are as the project moves along in the digital transformation journey.

An MES is central to a manufacturing business and evolves with it, transforming planned manufacturing into executed manufacturing. Watch our YouTube video on MES.