What is a Manufacturing Execution System (MES)?

A Manufacturing Execution System (MES) is a software platform that controls systems and monitors production of raw materials into finished goods on the plant floor. It provides real-time tracking of production activities, helping manufacturers optimise their operations by:

• Managing production scheduling
• Collecting real-time data from machines and processes
• Tracking inventory and resource utilisation
• Managing quality and strict regulations
• Identifying improvements in production efficiencies
• Providing detailed documentation for regulatory compliance

MES software integrates with Enterprise Resource Planning (ERP) systems to give manufacturers a comprehensive view of their operations, helping them to improve production cycle efficiencies and supply chain visibility to reduce costs, and enhance overall business performance.

• Collects production data throughout process control
• Monitors quality management checkpoints
• Provides documentation for quality assurance
• Identifies potential production bottlenecks and potential issues in real-time

MES solutions transforms manufacturing operations management across a range of industries by providing unprecedented visibility and control over business systems.

From the precision of automotive assembly lines to the stringent requirements of aerospace manufacturing, MES coordinates, monitors, and optimises every aspect of production operations.

Integrating MES will help manage complex manufacturing by optimising production process control systems and improving business operations through product tracking and supply chain management.

It's particularly valuable for mid-sized discrete manufacturers that provide a unique offering to their customers and have to manage extensive orders. Without MES, these manufacturers could face major constraints on the factory floor if jobs aren't managed efficiently.

• Reduces scrap and waste
• Minimises machine downtime
• Provides accurate job costing
• Reduces unnecessary inventory
• Optimises resource utilisation

While often confused, an ERP and MES work in tandem to drive operational excellence. Each system has a unique and essential role in operating a manufacturing business.

Understanding their distinct functions and how they interact is key to optimising production efficiency and business performance.

Essentially, an ERP provides a broader business management framework, while a MES provides granular, real-time manufacturing process management.

ERP provides a high-level overview of the entire manufacturing company, covering end-to-end business processes including estimating, quoting, sales orders, and production orders. It also manages warehouse and inventory location control and handles purchasing, delivery, and accounting.

MES provides a far more detailed view of the factory floor and more in-depth workflow scheduling. It offers more comprehensive quality guardrails, allowing a factory to almost "run itself" through detailed tracking of manufacturing process control systems.

MES is the basis of the Internet of Things (IoT) , integrating all manufacturing processes into a cohesive system in the factory. MES integrates with virtually everything in the manufacturing environment, including:

• Sensors
• Machines (telling the system what has or hasn't been done)
• Automated inventory systems
• Machinery controls

MES also supports broader system integration to provide a comprehensive, interconnected manufacturing management approach. MES integrates with:

• CAD systems
• Accounting software
• Sales systems
• Purchasing systems
• Shipment tracking systems

MES is a versatile system applicable across multiple industries, including food and beverage, pharmaceuticals, job shops, and discrete manufacturing.

Its adaptability makes it valuable wherever there are machines, integration challenges, and a need for constant quality monitoring and production rescheduling. It's most beneficial for businesses with multiple machines and intricate processes, typically ranging from small to mid-sized operations up to top-tier manufacturers.

For Australian manufacturers, MES systems provide significant advantages by helping companies manage extensive orders and unique production offerings.

When implementing a Manufacturing Execution System for the first time, employees might initially wonder if the MES system will replace them. MES is a tool to help them do their job more effectively. This advanced technology changes how work is done, with employees remaining essential in the manufacturing process, particularly in operating machines and managing production.

The psychological challenge of reorganising shop floor operations should not be underestimated. Employees may be accustomed to working in a "complex and confused state”. MES disrupts this by cleaning up and organising factory processes, which can be initially disorienting. The system transforms a chaotic production approach into a more logical and structured workflow.

The complexity of implementation also varies depending on a manufacturer’s current processes. Adapting to the new system can take time as employees adjust to a more logical and organised system. The MES helps by providing clarity and efficiency, but this transition can be challenging.

Despite these challenges, most manufacturers recognise the value of MES systems as a valuable tool to improve overall production capabilities.

Manufacturing Execution Systems will continue to evolve and help manufacturers to manage their entire business as cost effectively as possible, allowing them to produce more with the same resources.

From increasing automation and sophisticated data analysis to enhanced predictive capabilities and greater system integration, the future of MES is deeply intertwined with Industry 4.0. In fact, MES is the basis of the IoT in the factory.

• AI and Machine Learning in MES - while still in the early stages, AI and machine learning has the potential to transform MES by enabling machines to self-monitor, predict maintenance needs, and make automated decisions about tool replacement.
• Predictive maintenance with MES - enables machines to self-monitor their performance, autonomously tracking tool wear and initiating replacement processes, though this remains in its early stages
• The role of IoT in MES - enables full integration of manufacturing technologies, connecting sensors, machines, and software. MES using IoT enables manufacturers to have comprehensive, real-time visibility and control over their entire production environment, transforming how manufacturing operations are managed and monitored.
• How Industry 4.0 is shaping MES - goes beyond just manufacturing, potentially integrating, machinery, production, labour management, electricity and resource management and comprehensive business optimisation.

While the potential for "lights out" factory operations through MES technology exists, human oversight will remain crucial for strategic management, purchasing, scheduling, and performance monitoring.