A Manufacturing Enterprise System (MES) is a software-based solution that monitors and manages production operations on the shop floor. MES functions as a bridge in manufacturing operations management, connecting precise manufacturing processes with an organization's planning and control systems, such as SAP Business One.
You will be more easily able to meet customer demand and stay ahead of the competition by maintaining a lean, flexible manufacturing centre. Monitoring and documenting the transformation of raw materials to finished products in actual time is an important function of a MES. In order to provide accurate and up to date information on production status, it shall collect data from a variety of sources, e.g. machines, sensors or operators.
An MES enables stakeholders to monitor operations, identify obstacles, reduce interruptions, and make better decisions in a timely manner, providing real-time visibility and control over production processes. By streamlining optimized production planning and scheduling, the MES solution ensures capable resource allocation, workload balancing, and on-time deliveries, leading to high profitability.
By enforcing quality control procedures, monitoring metrics, and securing real-time data, they also play an important role in ensuring quality assurance and conformity. With their potential to manage inventory levels, track material movements, and ensure timely availability of materials, MES solutions optimize inventory management as well as reduce production delays.
Real-time data from different sources on the factory floor is captured by an MES software solution, used to monitor and control production processesA comprehensive overview of this process can be found here:
The system is collecting data from different sources, i.e. machines, sensors, operators and information systems like SAP Business One or Product Life Cycle Management Systems. This data shall include production rates, machine status, stock levels, quality measurements and many more.
The data gathered is analysed and consolidated in the MES solution, giving an overall overview of the production environment. This integration ensures that the MES has precise and updated information to work with.
Based on the production orders received from higher-level planning systems, the MES creates a production schedule. Factors such as order priorities, available resources, machine capacities, and labor availability are considered under this schedule.
This solution designates work orders to operators or workstations based on the schedule. It provides operators with instructions, specifications, and critical documentation to carry out their tasks. The solution monitors the progress of each work order and updates the work-in-progress status in real time.
Quality data is captured during production. There are stages such as measurements, inspections, and test results. It implements quality control procedures, triggers alerts or notifications for quality issues, and records quality-related information for analysis and traceability.
The collected data is analyzed to provide real-time information and performance metrics. It creates reports, dashboards, and visualizations that help management and operators make better decisions and identify areas for improvement.
The following are the essential features of our MES:
Purchase Process Flow Bill of Materials Process FlowProduction Process FlowMobile App Process FlowDispatch Process FlowShift Master Reason Master Machine MasterEmployee MasterComponent Routing Master screenBill of Materials screenWork order ScreenLogin Page Screen Machine check in Screen Work order Scanning ScreenMaterial Issue/Receipt ScreenSerial number allocation screen for issue/receipt Down Time Entry ScreenMachine Check out ScreenQC Scanning ScreenQC Check ScreenDispatch Pick & Pack screenDispatch screenDispatch serial number allocation screen SAP Posting FunctionsLogin Page ScreenHome screen User Profile ScreenUser Master Screen Master Screen Machine Release Screen Down Time Entry ScreenQR Code ScreenInputs / Outputs / Gap Analysis / Roles and Responsibility / Functionality Client Specific Alerts Client Specific RequirementsUse real-time data to monitor and analyze the status of resources, including machines, materials, and labor, to make allocation adjustments.
Optimize performance by scheduling, timing, and sequencing activities based on priorities and resourcing capacity.
Efficiently make quick and calculated adjustments to production planning by managing the flow of production data in real time
Manage and distribute documents, including work instructions, drawings, standard operating procedures, batch records, and much more, so that they’re accessible and editable.
Monitoring and controlling real time information on processes, materials, or operations to make informed decisions and enhance capabilities.
Monitor worker schedules, qualifications, and authorizations to optimize labor management with less investment of time and resources from management.
In order to improve the management of quality control and documentation, monitor quality deviations and exemptions.
Manage the complete production process, from order release to finished goods. Get insight into obstacles and points that impact quality while creating full production traceability.
Use data from your MES to identify possible equipment issues before they happen and adjust equipment, tool, and machine maintenance schedules to minimize downtime and increase capability.
Monitor the progress of your products and their genealogy for better decision-making. Having the data of a product’s complete history is extremely valuable for manufactures who must comply with government or industry regulations.
Compare results and goals to identify strengths and weaknesses in the entire process and use that data to make systems more capable.
Following are the benefits of the MES solution:
MES provides proper production optimization by giving supervisors access to real-time information. This includes the present state of the equipment in use, product trials, availability of resources, and so on.
A complete MES ensures consistency. Once an operation is performed, personnel can monitor it for improved security. It replaces paper-based documents, eliminates data redundancy, loss, and duplication.
Even in a controlled business environment, unwanted events can happen the may impede the quality of the final goods. MES ensures procedural enforcement to sustain shop floor capability.
When you provide quality and consistency in processes, it automatically improves customer satisfaction.
MES is an add-on that standardizes complete business operations with its top-notch functions. Shop floor personnel can implement, monitor, and record activities. This enables the supervisor to make timely decisions.
Seven digital transformation trends have created the evolution of MES solutions in recent years.
Cloud computing has gained traction in the manufacturing industry and MES solutions are increasingly being provided as cloud-based solutions. The benefits of cloud based MES solutions include scale, flexibility, minimum infrastructure costs and easier access to data from a variety of sources.
A notable trend is the integration of MES solutions with the Industrial Internet of Things. IIoT technology is used in MES solutions to gather data from sensors, machines and connected devices at real-time. This integration enables improved visibility, predective analytics, remote monitoring and optimization of discrete manufacturing processes.
MES solutions are using big data analytics efficiencies to process and analyze the large amount of data generated in manufacturing operations. Advanced analytics algorithms and machine learning techniques are applied to identify patterns, correlations, and actionable visions.
In order to be able to access data and functions from smartphones and tablets at any time, applications are increasingly integrated in MES solutions. The operators, supervisors, and managers are able to monitor the production process, view production dashboards, as well as get notifications on their mobile devices
MES solutions are developing their integration efficiencies to connect with supply chain systems. This integration enables seamless information flow between MES, ERP, and SCM systems, allowing improved supply chain visibility, demand planning, and synchronization. It allows better coordination with suppliers, customers, and logistics partners.
AI and machine learning technologies are being applied in MES solutions to automate decision-making, optimize processes, and allow predictive efficiencies. AI algorithms can analyze historical data, identify deviations, forecast production outcomes, and suggest process improvements.
MES solutions are focusing on providing instinctive user interfaces and advanced visualization efficiencies. Interactive dashboards, 3D visualization, augmented reality, and visual reality are being included to improve the user experience and streamline a better understanding of production data.
Technologies like SAP Business One allow modern manufacturers to access many of the key features without the common challenges of MES. With Zyple Software as a SAP B1 Partner, features of MES are specifically designed and developed by those near operations.