Eight steps for the successful introduction of the SAP Digital Manufacturing MES solution

The central tool for successful digital production is called MES – Manufacturing Execution System. A powerful MES makes it possible to monitor production processes in real time, use resources more efficiently, optimize production performance and thus increase added value.

However, implementing an MES system involves much more than just installing a software solution. While the system itself is of great importance, a well-thought-out implementation strategy is particularly important in order to achieve the greatest possible benefit. Practical examples show that the effort is worthwhile.

Practical examples: Added value through the correct use of MES

Fulfilling reporting obligations more easily: The BWF Group, a long-established family business from Bavaria, uses an MES to produce more resource-efficiently, reduce costs and meet increasing legal requirements such as the German Supply Chain Act and the European CSRD Directive on sustainable production.

Increasing energy efficiency: A US automotive group digitally combines MES key figures by linking the energy data of the machines with their overall equipment effectiveness (OEE). In this way, the most energy-efficient machine is selected for each order, which not only protects the environment but also saves costs.

Ensuring on-time delivery: An automotive supplier that produces painted plastic parts for a premium manufacturer uses MES to ensure on-time delivery according to the just-in-sequence principle. This ensures that all parts arrive at the assembly line exactly according to the production plan.

Proceed in a structured manner

A structured approach is required in order to derive the greatest possible benefit from an MES system. This requires comprehensive planning that takes technical, organizational and personnel aspects into account.

When implementing SAP Digital Manufacturing (SAP DM), the experts at FORCAM ENISCO rely on a proven eight-step procedure that can also be transferred to other MES systems.

1) Strategy: Developing a vision

Every company has specific production requirements. Important aspects such as process quality, throughput times or machine availability must be defined in order to develop a clear target image and corresponding milestones.

Added value: Market requirements and operational necessities are harmonized.

2) Explore: Clarify requirements

An MES affects numerous areas of the company. An interdisciplinary team from IT, production, quality assurance and management analyzes which functions are required and which IT developments are necessary.

Added value: Overview of required resources and costs incurred.

3) Know-how building: involving employees

The success of a project stands and falls with the people who drive it forward. Iterative training and early and transparent communication maximize the benefits of the new processes.

Added value: The teams are involved and motivated to actively use the new solution.

4) Scoping: concretize project planning

Clear definition of objectives, responsibilities and budgets with detailed breakdown into micro-projects and milestones.

Added value: The project can start because everyone involved knows the objectives and processes.

5) Implement project and introduce MES step by step

A pilot project in a small, defined production area with 3 to 5 machines enables a controlled test phase and adjustments before the system is fully rolled out.

Added value: The main production continues undisturbed, initial improvements motivate all teams and facilitate the subsequent rollout.

6) Support and release management

Support and regular system updates are critical to success in order to ensure the smooth integration of the MES into the IT landscape and communication with existing systems such as ERP, PLM or SCADA.

Added value: Efficiency and reliability increase measurably because the data exchange between the systems functions smoothly.

7) Know-how transfer

Repeated training courses and workshops ensure that all employees involved can make optimum use of the software solution and are always familiar with the latest developments.

Added value: The teams are empowered to use the MES software independently and optimally in the long term.

8) Continuous optimization with CIP

After the go-live, the phase of continuous improvement begins. The production data from the MES is regularly evaluated and optimization potential is identified.

Added value: Production and processes are sustainably optimized, waste is reduced and efficiency is sustainably increased.