A manufacturing execution system (MES) explained simply
An MES (manufacturing execution system) is a software system that monitors and optimizes the manufacturing process in industrial production in real time. It collects data directly from machines, sensors, and employee input. The aim is to improve the efficiency and quality of overall production. An MES is the central data hub of a smart factory.
The most important facts at a glance
- An MES provides a precise and up-to-date overview of the production status. It monitors, documents, and controls the entire manufacturing process, from the procurement of raw materials to the delivery of the finished product.
- The main functions of an MES include production control and detailed planning, performance measurement, material management, quality control, and personnel management. These functions are crucial parameters for optimizing manufacturing processes in a targeted manner.
- In order to optimize production efficiency and quality in the long term, it is critical to integrate shop floor and top floor systems, i.e., to integrate the MES from the factory (shop floor) with corporate planning (top floor). The latter systems are collectively referred to as “enterprise resource planning” (ERP).
What is an MES?
A Manufacturing Execution System is also known as a production control system. An MES as a production control system (Manufacturing Execution System) is a complex information system that monitors, documents, and controls the entire manufacturing process—from raw material procurement to the finished product.
The MES uses real-time data from various sources, including machines, sensors, and employee input, to provide an accurate and up-to-date overview of the status of production activities.
The role of an MES goes far beyond mere data collection. It enforces quality control procedures and continuously monitors metrics to ensure quality assurance. It integrates other process control systems and thus acts as a functional layer between ERP (Enterprise Resource Planning) and the process control systems.
In addition, an MES enables:
- seamless integration with other enterprise systems such as Enterprise Resource Planning (ERP),
- a comprehensive view of the entire production process
- significantly easier production planning and control,
- a significant reduction in errors and inefficiencies.
In regulated industries, product manufacturing must be comprehensively documented to ensure traceability and product safety. The data and analysis capabilities of an MES ensure this.
How does an MES work?
The functionality of an MES is rooted in the integration and analysis of data from a wide variety of sources. This data comes from ERP systems at the company level on the one hand, and directly from the machines and inputs on the shop floor on the other. This enables comprehensive monitoring and control of the production process.
An MES records data from the sources in real time and manages tasks by assigning them to employees or workstations and tracking progress in real time. All process-controlled data is digitally mapped. The data is analyzed and provides real-time insights and performance metrics through regular reports in digital overviews (dashboards).
A powerful MES tracks material flows and ensures that all necessary raw materials and parts are available on time. In addition, the MES monitors quality measurements and triggers automated alerts in case of problems. The MES provides the responsible persons with all relevant data to make informed decisions and optimally control production.
Advantages of an MES
The implementation of a manufacturing execution system offers a variety of advantages that go far beyond the mere monitoring of individual processes.
Increase efficiency, reduce costs:
One of the biggest advantages is that MES helps to increase process efficiencies and reduce costs in manufacturing. Companies can work more efficiently through improved inventory management and reduced storage costs, thereby significantly lowering their production costs.
Product quality:
Another key advantage of an MES is that it improves product quality. Real-time monitoring and ongoing adjustment of production allow quality issues to be identified and resolved at an early stage. In addition, an MES enables informed decision-making by providing detailed production data and analyses that can be used to optimize manufacturing processes.
Transparency and real-time insights:
By using an MES, companies gain a clear overview of the entire production process. Advantage: Factory teams can react more quickly and flexibly adapt processes to new circumstances. These real-time insights also help to increase production efficiency and save costs.
Core functions of an MES
Certain core functions of a manufacturing execution system (MES) are central to the optimization of production processes.
Examples:
Traceability (track & trace) is a must in modern factories: the seamless tracking of every component, every product, and every process at all times. With a powerful traceability application, factory teams can determine how and where a product or component was manufactured at any time. This helps to meet regulatory requirements and minimizes product liability risks.
Detailed scheduling: One of the most important functions is detailed scheduling. It enables precise planning and control of production, avoids bottlenecks, and maximizes efficiency. With the detailed scheduling function, factory teams can make optimal use of existing resources—the planning effort can be reduced by up to 70 percent.
Quality control is an essential part of an MES. A modern MES improves quality in real time through visualization and reporting: Quality data is collected, analyzed, and visualized, and the causes of errors are made transparent. This enables a quick response to quality issues and contributes to the continuous improvement of product quality.
Personnel scheduling plays an important role by providing information on when and whether qualified personnel are available for the production process on time.
Material management is another central function of an MES. It ensures that production is supplied with the necessary materials on time and as needed. The material flows of raw materials can be tracked precisely to the finished product. Bottlenecks are avoided and materials can be provided just in time. This contributes significantly to the success of overall production.
These and other MES functions help to make production more efficient and ensure the quality of the manufactured products.
MES architectures
Today’s MES architectures offer a variety of models that meet the different requirements of companies. Traditional MES architectures are often based on a classic client-server model, in which communication takes place between a central server and multiple clients.
Cloud-based solutions have become increasingly popular in recent years because they offer numerous advantages. In a cloud-based solution, many servers share the work, which contributes to load balancing and reliability. These solutions can be operated either in the company’s own data center or at an external provider, whereby secure communication via HTTPS is crucial.
Private cloud MES solutions, which run directly in the respective company’s data center, offer additional security and control.
These different architectures enable companies to choose the solution best suited to their specific needs and maximize the flexibility and scalability of their MES systems.
Integration of MES and ERP
The integration of MES and ERP solutions, i.e., manufacturing execution systems and enterprise resource planning systems, is crucial for transparent and efficient manufacturing. An MES functions as a functional layer between ERP systems and process control systems. The MES forms the layer between the processes of ERP enterprise resource planning and manufacturing. An interface to third-party systems is also a hallmark of a modern MES.
The integration of MES and ERP gives manufacturers a comprehensive and transparent view of the manufacturing processes. Such a production control system is an important component for the efficient and successful overall manufacturing process.
Another advantage of integrating MES and ERP is the reduction of inventory. Automated messages to the ERP system provide a better overview of the material flow and enable savings in manufacturing, transport, and storage. Seamless integration of MES and ERP thus contributes significantly to increased efficiency and cost reduction.
Challenges in implementing an MES
The implementation of an MES brings with it numerous challenges that must be carefully addressed. One of the biggest challenges is integrating not only existing ERP systems, but also systems for quality management (CAQ) and maintenance. This requires clear guidelines for data management and effective communication between the systems.
Planning and security requirements are also important aspects that must be taken into account when implementing an MES. Inadequate planning can lead to poor results, while increased cybersecurity is necessary to protect industrial companies from cyberattacks.
Implementing an MES requires not only technical expertise, but also close cooperation between the various departments of the company to ensure that the MES system meets specific requirements.
Trends and new technologies in the MES sector
The field of manufacturing execution systems is constantly evolving, with new technologies offering attractive opportunities for innovation. One of the most notable developments is the use of cloud technology in MES systems.
This offers, for example,
- immediate availability,
- global scalability,
- low-cost acquisition and installation.
The possibilities offered by innovative apps from the Industrial Internet of Things (IIoT) sector are another significant trend.
IIoT apps enable, for example,
- complete process automation,
- real-time monitoring and optimization of production processes,
- the use of innovative technologies such as sensors and autonomous interactions.
These technologies make it easier for companies to remain competitive in a digital world. Another exciting trend is technologies for predicting events, often summarized under the heading of digital twin technologies. Predictive models created with the help of artificial intelligence (AI) and machine learning can predict future problems and thus avoid costly downtime. Making decisions that are data-driven and based on automated analyses and alerts will play an important role in the factory of the future.
Tips for successfully implementing an MES
Successful implementation of an MES requires careful planning and execution. An important first step is to identify the specific needs and goals that the MES should fulfill. These include goals such as increasing efficiency, improving quality, and meeting compliance and regulatory requirements.
The introduction of an MES should be done in small steps. It is most beneficial to start and test the MES in a limited area first. It is best to test the MES on critical equipment first in order to achieve immediate improvements and strengthen employee confidence in the new system. Quick optimization successes help to successfully roll out the MES step by step.
Open and early communication about the MES project is crucial to involve all stakeholders and clarify any fears or concerns in advance. In addition, training employees in the new technologies and systems is of great importance in order to overcome labor shortages and promote acceptance of the MES as a comprehensive system.
Targeted training programs and the implementation of change management strategies play a key role in ensuring the successful introduction of an MES.
Practical MES case studies
Reference reports from companies offer valuable insights into the practical application and results of MES systems. Examples from FORCAM ENISCO customers demonstrate how companies have been able to track and optimize their entire process chain by using our MES FLEX solution and developing MES standards—with a wide range of benefits such as greater efficiency and compliance with regulations and ISO standards.
From paper to digital production (machining)
In this success story, you will learn how the medium-sized company LOEW Präzisionsteile GmbH in Nuremberg is producing more efficiently with digital manufacturing and the MES FLEX solution.
Fulfilling reporting requirements more easily (textile and plastics industry)
Learn how the BWF Group from Bavaria, a global specialist in the textile and plastics industry, is sustainably optimizing its production with our MES solution.
Doubled capacity utilization (medical technology, aerospace)
In this reference report, learn how Swiss company MPS AG is significantly and sustainably increasing value creation in manufacturing with digital technology from FORCAM ENISCO.
Summary
Powerful manufacturing execution systems, such as FORCAM ENISCO’s MES FLEX solution, play a central role in modern manufacturing. They offer comprehensive solutions for monitoring, controlling, and optimizing entire production processes. The advantages of an MES are manifold and include cost reduction, increased productivity, improved quality, and real-time insights.
The successful implementation of an MES requires careful planning, open communication, and continuous employee training. With the right strategies and technologies, companies can make their production processes more efficient and hold their own in the highly competitive manufacturing industry. Be inspired by the possibilities and leverage the potential of an MES to future-proof your manufacturing.
