What is a Manufacturing Execution System?

Efficient manufacturing processes are crucial for ensuring cost-effectiveness, productivity, and quality in industrial operations. A Manufacturing Execution System (MES) plays a critical role by providing real-time monitoring, control, and optimization of production processes to streamline production, minimize waste, and enhance overall output. Maveneer can offer a variety of solutions for manufacturing operations, but deploying an MES can often be the first step to opening up additional opportunities for holistic operational improvement.

What is a Manufacturing Execution System (MES)?

A Manufacturing Execution System (MES) is a software system that manages and controls manufacturing operations real-time to improve efficiency and productivity. MES Systems integrate with Enterprise Resource Planning (ERP) and Supervisory Control and Data Acquisition (SCADA) systems to track raw materials, manage material flows and task assignments, and provide insight into manufacturing quality and productivity measures. By integrating these functions, MES optimizes a facility’s manufacturing operations with the key objectives of providing visibility to system performance, offering additional control on operational performance while increasing productivity and profitability.

How Does an MES Work?

There are several core components of an MES. They span areas including production task assignments and scheduling, shop floor control and documentation, and quality, maintenance, and inventory management. A fundamental element of every MES is the focus on real-time data collection and monitoring that provides decision-makers insight into details from the shop floor such as machine status, work progress, and inventory levels. The data may be input manually by employees or automatically recorded via connection to sensors managed by SCADA systems. Ultimately, a quality MES is highly customizable for the end user’s application. Modules, dashboards, and reports can be adapted to suit the specific needs of the operation regardless of the industry.

Benefits of MES Systems

• Production Visibility: Live data reporting gives management a clear picture of current order status and productivity rates
• Live Status: An effective system provides reporting capabilities to quickly escalate problems to operators and managers for rapid resolution (e.g., inventory level issues, high package dwell times putting service level at risk, staffing imbalances). This helps to improve customer experience and operational efficiency. 
• Traceability: Many WMS options can integrate with other internal and external data sources, such as Enterprise Resource Planning (ERP), Order Management Systems (OMS) or Transportation Management Systems (TMS). This provides an opportunity to access and integrate data across the organization. 
• Document Control: Digital record-keeping reduces paper on the shop floor to improve accuracy, accessibility, visibility, and edibility.
• Reduced Costs: The optimized material flows and labor distribution lead to a reduction in operational costs and increased worker productivity throughout the facility. 

How to Implement an MES

Implementing an MES involves several key steps, each critical for a successful transition:

1. Assess Current Operations:

Begin with a thorough assessment of your current manufacturing operations. Identify inefficiencies, pain points, and areas for improvement. Understanding your existing processes is essential for designing a tailored MES solution.

2. Define Requirements and Objectives:

Clearly outline your requirements and objectives for implementing an MES. What specific challenges are you looking to address? What goals do you aim to achieve? Defining these parameters will guide your MES selection and implementation strategy.

3. Vendor Selection:

Choose an MES provider that aligns with your needs and objectives. Look for vendors with a track record of successful implementations and a commitment to customization and support. Consider factors such as solution flexibility, scalability, and compatibility with existing systems.

4. Customization and Integration

Work closely with your chosen vendor to customize the MES to suit your unique requirements. Ensure seamless integration with existing ERP and SCADA systems, minimizing disruptions to ongoing operations.

5. Data Migration and Validation

The WMS automates the packing process by providing instructions to staff based on order details, item dimensions, and packaging requirements. This supports the operator in quickly selecting the appropriate packaging material to minimize waste and reduce packaging costs. The WMS can incorporate quality control checks during the packing process to verify that the correct items and quantities are included in the package, preventing errors, and improving customer experience.

6. Change Management and Training

Prepare your workforce for the transition by implementing effective change management strategies. Communicate the benefits of the new MES system, address concerns, and provide comprehensive training to ensure smooth adoption. 

7. Phased Implementation

Consider a phased approach to MES implementation to minimize disruptions and facilitate gradual adjustment. Roll out the system in stages, starting with pilot testing in select areas before scaling up across the entire operation.

8. Continuous Monitoring and Improvement

Once the MES is operational, monitor its performance closely and solicit feedback from users. Identify areas for optimization and refinement, leveraging the MES's flexibility to adapt to evolving needs and challenges.

Integrating MES Systems with an ERP

Integrating ERP (Enterprise Resource Planning) with MES (Manufacturing Execution System) systems is essential for improving manufacturing operations. ERP manages finance, procurement, and inventory, while MES focuses on real-time production monitoring. This integration enables seamless exchange of information like schedules and inventory levels. By automating data transfer, workflows become smoother, errors decrease, and efficiency improves. This collaboration allows businesses to make informed decisions, allocate resources effectively, and respond quickly to market changes, giving them a competitive advantage.

Challenges of MES Implementation 

Two of the most common challenges when implementing a new MES in an existing manufacturing operation are tied to systems integration and people management. 

Existing enterprise systems can be cumbersome and difficult to interface with, so it is important to plan adequate time for the MES provider to develop and test the interface between these systems. Data sources, whether manually input or automatically collected, should also be validated for accuracy prior to implementing the MES to reduce the risk of potentially confounding results post go-live. A risk assessment can go a long way to call out the potential systemic stumbling blocks before any changes occur. 

Even if the systems come together, human nature and resistance to change may still stand in the way of a successful MES implementation. Transparent communication from the implementation team regarding the impact to employees, rollout schedule, change management leaders, and anticipated benefits can help smooth social concerns. Implementing new processes linked to MES in stages can also help make the overall change more digestible to employees. 
 
Systemic and employee-related challenges can linger even after the MES and associated new processes have been successfully adopted. Post-implementation, ongoing support and maintenance are crucial to keep the MES operating at its highest capacity and delivering maximum returns.

Selecting the Right MES Systems Provider