How Manufacturing Execution Systems Shed Their Legacy Limitations and Became Essential

Manufacturing execution systems (MES) developed a reputation for being too rigid, expensive and out of sync with modern manufacturing operations. But now, as supply chain issues, economic pressures and compliance requirement demands intensify, MES is making a strong comeback and shedding its cumbersome image. 

With this in mind, it’s important to clarify MES, which is a broad term for a software platform to monitor and manage operations in a manufacturing environment. MES provides real-time data and analytics of production processes, allowing for a strategic overview of operations that supports continuous improvement activities.

It’s different from other automation technologies, such as SCADA and distributed control systems, because MES does not perform any direct control of equipment. But in today’s manufacturing world, where the importance of real-time, data-driven decision-making has become clear, there’s growing recognition that MES is essential. It’s the tool that bridges the gap between big-picture business goals and day-to-day production realities. 

Has MES Really Changed Much? 

Traditional MES options were inflexible and vendor-specific, often coming from the same major vendors of industrial automation hardware and software. Connectivity options were limited, making it difficult to get production data.

Legacy MES deployments were expensive, and software limitations often meant that the entire functional model had to be designed at once, requiring manufacturers to commit to a large amount of functionality upfront. Expanding and upgrading systems was difficult and often also heavily dependent on vendor support. 

In contrast, modern MES offerings more closely resemble IT software that operators are used to outside of manufacturing, with lightweight web clients, cloud deployment options, modular functionality and AI/ML features. This allows for integration with other business software platforms.

"Modern MES more closely resemble IT software that operators have become used to outside of manufacturing, with lightweight web clients, cloud deployment options, modular functionality and AI/ML features."

• Variability in raw material costs is a huge issue in manufacturing. Use MES to track material usage in real-time and minimise waste. 
• Monitor equipment performance to better schedule planned maintenance activities, minimising production downtime. 
• Digitise paper-based checklists and workflows to improve data availability and reduce the risk of human error. 
• Analyse quality data so processes can be corrected before products become out of specification. 

Where to begin with MES today

The starting point is getting clarity on what you’re trying to achieve by implementing an MES.

Identify your major concern, such as cost, quality, schedule adherence, traceability or uptime. It is tempting to say all of these, but the best results will be achieved by more clearly defining success and scope by picking one to two of these.

At Nukon, we help customers solve their business problems through the application of technology, not by implementing technology and then looking for problems to solve. We always recommend identifying the problems the business or users are facing and then working backwards towards the technology.

The bottom line is your MES journey doesn’t have to be complicated. Working with a digital advisory partner on a strategy-led approach makes transformation much more achievable.

About the author:

Amy Sudibyo is a Technical Lead at Nukon, and has more than 12 years' hands-on experience in electrical and software engineering. 

Amy has worked across a wide range of industries, including energy, water, and manufacturing - from food and beverage, to packaging, construction materials and pharmaceutical.

She has successfully implemented MES for iconic Australian manufacturers of fast-moving consumer goods and solved numerous data visibility challenges for clients. Amy has a keen focus on technology that enables and supports efficiency and continuous improvement for operators and management. 

Within Nukon, Amy sets the technical vision and guides the delivery of software engineering for projects, ensuring best practices are implemented for clients.

This article also appeared in Automation World. 

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