Manufacturing Execution System (MES) solutions have, over time, become essential for companies wishing to optimize production and ensure efficient process control. But what exactly are MES systems and how do they work? And most importantly, how do we choose the most suitable one for our enterprise? Let’s find out, through five tips that are valid both for companies that need to equip themselves with a manufacturing MES for the first time and for those that have a change in sight.
What is an MES system?
MES, or Manufacturing Execution System, is a computer system used to manage and monitor production processes, in a manufacturing environment. These systems collect real-time data from machinery and operators, providing detailed visibility into the workflow and allowing companies to have complete control over the production line and the entire supply chain. The main objective of an MES is to ensure that production is performed as efficiently as possible, reducing waste and maximizing productivity. This is done through a number of features, including production planning, resource monitoring, quality control, and performance analysis.
Solutions in this area do not stop at MES software. Typically, in fact, it is a system that integrates machinery, plants or factories, operators and production processes. It monitors activities in real time, collecting valuable data to ensure high-quality products. Integration of the MES with other digital tools such as ERP and PLM enables real-time analysis and monitoring of production steps. Beyond the strictly technical and descriptive aspects, in order to make the most of an MES, it is essential to understand its functionality and know how it can adapt to a company’s specific needs.
The main advantages of MES systems
MES systems actually act as an interconnection between an enterprise’s planning and control systems and real-world manufacturing operations. This is why they are vital in smart factories to track and document the transformation of raw materials into finished products. By collecting data from machines, sensors and IIoT devices, they provide clear and comprehensive visibility of manufacturing activities. These systems facilitate production optimization, ensuring efficient management of resources and on-time order management, improving profitability. They play an essential role in quality management and compliance by monitoring metrics and capturing data in real time. MESs provide accurate production data, supporting data-driven decisions and measuring the overall effectiveness of production tools.
For these reasons, before choosing and implementing an MES system, it is essential to make a series of substantive assessments of one’s production reality and systematize them with the characteristics of the products offered by the market. Although this is a choice that has important margins of subjectivity, here are some general tips that can help guide the choice.
1 Understand the key functionalities of an MES system.
As we have mentioned, MES solutions also consist of powerful software systems used to improve capacity, quality, delivery and visibility. Before choosing, it is essential to understand the key functionalities that the MES must offer to fit our production reality. Once these minimum requirements have been identified, it is possible to proceed by cross-referencing them with market offerings and, through one’s trusted system integrator, assess what adaptations can be made to get as close as possible to the desiderata, and then determine whether any differences can be mediated.
2 Evaluate integration with other systems
An effective MES should be able to integrate easily with other systems such as enterprise resource planning (ERP). This integration provides real-time visibility and control throughout the supply chain, ensuring a consistent flow of information and reducing the possibility of errors. Once information about the data environment is deepened, the MES can be integrated with the enterprise digital core. In addition, the system should effectively integrate not only with ERP but also with other systems already in place: PLC and SCADA, for example. Finally, the dashboard should be simple and clear to understand, equipped with all essential information and with the ability to interface with operational tools for more agile control.
3 Consider scalability and flexibility
Each company has its own specific needs and goals. Therefore, it is critical to choose an MES system that is scalable and flexible, able to adapt to the changing needs of the business and grow with it. Mapping the flow of data between systems and processes will identify gaps and opportunities. With regard to customizations, it is imperative to ensure that the partner or system integrator chosen works according to the latest best practices outlined by the vendor. For example, implementation strategies such as back-to-standard or clean core must be taken into account in any customization, even the simplest ones.
4 Examine analysis and reporting skills
Analysis, data comparison and reporting are essential for making data-driven operational and strategic decisions that are critical to today’s competitiveness. A good MES system should offer advanced tools for data analysis, enabling decision makers to get a clear view of production and quickly identify areas for improvement.
5 Support, communication and collaboration
Choosing an MES system is only the beginning. It is essential to have strong after-sales support, with regular training, service and updates. Communication and collaboration with the MES vendor are crucial to ensure that the system remains efficient and up-to-date.
A strategic choice
Choosing an MES system is a critical decision for any company in any manufacturing sector. By following these tips and taking the time to carefully evaluate your options, you will increase the chances of selecting an MES system that aligns with your business goals and contributes to your manufacturing success.
Request an appointment with one of our consultants to find out how to integrate the MES system into your company’s production process.
