The variability of modern manufacturing, the complexity of manufacturing processes, and the pressure to drive productivity and profitability typically require most manufacturers to invest at some level in the automation of manufacturing execution. Technically, all manufacturers use some form of an MES, but to what degree and the sophistication of the system varies greatly. Let’s look at what an MES is and how today’s systems can help manufacturers achieve greater optimization.
What is a Manufacturing Execution System (MES)?
A manufacturing execution system (MES) is a software solution designed to uphold quality and efficiency throughout the manufacturing process. Execution in manufacturing happens at both the plant and manufacturing levels. These systems connect multiple plants as well as live site and vendor production information. They also integrate with equipment, controllers, and other enterprise software applications to provide ultimate visibility, efficiency, and control across all manufacturing operations. Put simply, MES software capability revolves around three basic elements of manufacturing: production orders, human resources and equipment.
How Has the Manufacturing Execution System Evolved?
In 1997, the Manufacturing Enterprise Solutions Association (MESA) International defined the scope of MES through the MESA-11 model. As an organization that seeks to improve operations management through effective IT application, MESA’s earliest model indicated 11 core functions of an MES, including:
- Operations management
- Dispatching production units
- Product tracking and genealogy
- Labor management
- Quality management
- Maintenance management
- Data collection and acquisition
- Process management
- Performance analysis
- Document control
- Resource allocation and status
In 2004, the MESA model was expanded to include business operations. This update, known as Collaborative MES or C-MES, merged core operations with business operations to take into account competition, outsourcing and asset optimization. The goal was to link MES solutions with other areas, such as supply-focused systems, customer-focused systems and performance-focused systems, such as ERP.
Industries Utilizing Manufacturing Execution Systems
MES is utilized across multiple industries, but a few examples of rapidly growing fields include:
- Industrial Manufacturing
- Food and Beverage
- Consumer Products
- Electronics and Tech
- Pharmaceuticals and Medical Devices
MES supports complex process workflows, high-volume automated data collection, make-to-order, discrete assembly, batch process, rolled products and more. The principles of MES are relevant to the entire manufacturing industry. For instance, MES provides materials traceability. This traceability is required by industries such as Food and Beverage, Medical Devices, Aerospace and more to ensure compliance. Paired with a manufacturing ERP system, a quality MES can transform a manufacturing enterprise, streamlining operations across the entire business.
Benefits of a Manufacturing Execution System
Why is MES so valuable? Here’s why MES systems are beneficial to manufacturing plants and factories.
Improved Efficiency & Reduced Waste
Having an MES will help detect any inconsistency or inefficiency on the shop floor. This will quickly stop processes to correct the issue, reducing wasted material and unnecessary expenses.
Decreased Downtime
MES solutions create realistic production schedules and track raw materials and parts inventory. This prevents having to reconfigure schedules while parts are in transit and allows you to schedule staff more effectively.
Digitization & Data
Recordkeeping can be done in real-time from the shop floor with an MES. Not only does this cut down on paper notes and spreadsheets, it allows you to collect valuable data to evaluate your business model and forecast prices.
Reduced Costs
Having that real-time data enables decision-makers to act more strategically. When you’re able to make more informed decisions, you can save on costs on orders, free up personnel from operation production lines and controlling inventory and improve all-around efficiency.
ERP Integration
As shown in the MESA model, MES easily integrates with ERP systems. That means there’s no need for stand-alone systems and data re-entry across applications. With connected systems, you gain better visibility into operations, can make more accurate projections and improve decision making.
How Do MES and ERP Work Together?
MES and ERP systems have distinct but complementary roles when it comes to manufacturing. MES bridges your shop floor and your planning and logistics systems, which are essentially an ERP solution. MES will evaluate areas like machines and supervisory systems. An ERP system will look at needs like planning and scheduling.
Essentially, ERP systems bring all facets of your enterprise into one comprehensive information system. With an ERP, you can see all your connected business operations, how each one is doing, how they interact, and what real-time data about each of these areas is telling you about your processes and assets. MES is just one piece of that ERP puzzle. An ERP system can show you that there’s a production issue; an MES will show you the specifics of how to solve it.
When an MES and ERP work together, you have a full view and a single source of truth about your organization. This is how manufacturers streamline their operations and stay competitive in a growing and changing business environment. QAD Adaptive ERP is designed to help manufacturers across a variety of industries gain greater visibility and control to achieve better all-around success.
To learn more about QAD Adaptive ERP and how it can help optimize your manufacturing enterprise, visit our website.
