Efficiency drives profitability, and manufacturing waste significantly hampers both. But investing in a manufacturing execution system, or MES software, transforms this challenge into an opportunity for improvement.
In this how-to MES guide, we’ll detail everything you need to know about this software, its benefits, and how integrating it with Fishbowl can streamline your manufacturing operations.
What does MES stand for?
A manufacturing execution system — or MES solution — is a technology that optimizes manufacturing processes for enhanced efficiency and quality. It integrates data from various sources, like equipment, workforce, and production orders, into a cohesive system. This integration provides a clear and comprehensive view of your manufacturing operations, enhancing your ability to:
- Manage workflows
- Rectify bottlenecks
- Maintain consistent production quality
- Improve inventory control
MES systems can significantly boost performance in many industries, including:
- Medicinal products
- Edibles and drinks
- Healthcare instruments
- Aviation and space exploration
- Military and security
- Life sciences
- Vehicle manufacturing
What are the modules of a manufacturing execution system?
MES functions differ in objective and scope depending on their manufacturing environment, but every solution should have these core elements.
Data collection
Modern MES systems pull data from other platforms they integrate with, like manufacturing inventory management software, to provide operational insights. With greater visibility, you can make informed, agile decisions that keep production on track.
Quality control
MES solutions offer real-time access to production data, including metrics like the first-time-right score (the percentage of products made correctly without rework). They also send alerts when problems occur, so you can act quickly to correct them.
Product tracking
MESs use sensors and data analytics to track materials across the production cycle. This helps you ensure each ingredient or component meets quality and compliance requirements.
Performance analysis
Leading MES solutions continuously analyze your manufacturing process, alerting you to deviations from set productivity benchmarks.
Maintenance management
MES systems monitor equipment usage patterns and wear-and-tear indicators. Then, they suggest optimal service windows that prevent unexpected breakdowns and minimize downtime.
Resource assignment
MES platforms track equipment availability, inventory, workforce capacity, and job priority, so you can deploy the right tools and people where they’re needed most.
Production scheduling
With the real-time data that MES systems provide, it’s easier to coordinate feasible production timelines. The software accounts for production goals and resources, which helps you adjust schedules as conditions change to keep operations running smoothly.
Workforce administration
MESs include tools that track employee skills, certifications, and availability. That way, you can assign tasks based on qualifications and ensure coverage without overstaffing or compliance risks.
Record governance
MES solutions store and organize your documents — including production records, quality reports, and compliance data — in one central, easy-to-access location.
Inventory oversight
By monitoring stock in real time, MESs give you greater visibility and control over your inventory.
Top 6 benefits of using a manufacturing execution system
MESs bring numerous advantages to your organization; here are the top six.
1. Improves visibility
By integrating data from order processing systems, inventory management tools, and smart machinery, MESs provide a comprehensive view of operations. With greater clarity, you can quickly identify inefficiencies and make informed decisions to optimize production.
2. Ensures error-free production
MESs deliver real-time, uniform guidelines and procedures across different shifts and teams, helping you minimize production errors. For example, you can use an MES to automatically update production protocols, ensuring every team member follows the same procedures.
3. Enhances operational agility
MESs provide visibility into your human and material resources, workflows, and productivity levels. With these insights, you can respond more quickly to changing customer demands or unexpected material shortages.
4. Boosts inventory management accuracy
MESs elevate inventory control by providing granular insights into raw material usage and the status of semi-finished goods. These details help you anticipate and fulfill inventory needs.
5. Increases traceability and compliance
MESs serve as repositories for all inventory data, which improves the traceability of your materials and products. As a result, you stay compliant with industry regulations and protect your brand’s integrity.
6. Improves organizational communication
MESs provide a singular source of truth for all departments, from factory workers to maintenance staff and executive decision-makers. This boosts collaborative problem-solving, which drives operational efficiency.
3 challenges of implementing manufacturing execution system
When introducing an MES, understanding potential roadblocks is key to a successful implementation. Let’s look at three major challenges you might encounter and best practices for overcoming them.
1. Implementation and integration
Deploying an MES solution involves extensive setup and customizations to align with your specific needs. The process can span weeks, requiring you to configure and integrate the system with your existing applications. And if your chosen MES doesn’t offer compatible integrations with your core business software, creating custom integrations can be costly and time-intensive.
To overcome this, meticulously plan the implementation process and make sure you allocate enough time and resources. Working with MES providers who offer solutions with pre-built integrations, like Fishbowl, can also simplify implementation.
2. Business process adaptation
Introducing an MES into your manufacturing operations can initially be disruptive, potentially meeting resistance from staff accustomed to existing processes. This makes proactive change management strategies key. Providing comprehensive training, demonstrating the benefits the MES provides, and having open discussions to help staff understand its positive impact can smooth the transition.
Involving team members in the planning and implementation stages is also critical, as it fosters ownership and engagement with the new system. Regular feedback sessions and support structures can further help address any concerns or challenges.
3. Data security risks
Centralizing business data with an MES makes it more accessible, but it also becomes a more attractive target for cybercriminals. This makes prioritizing data security during implementation critical to protect sensitive information.
Enhance your cybersecurity framework by implementing advanced security measures such as encrypted data transmission, multi-factor authentication, and regular security audits. Educate your team about cybersecurity best practices, like strong passwords, and consider partnering with security experts for continuous monitoring and support to protect your data as you transition to and use your new MES.
How an MES and ERP work together
An enterprise resource planning (ERP) system is a powerful business management solution that streamlines various organizational facets into one unified platform. ERPs typically use a modular architecture, enabling customization with specific modules tailored to your organization’s needs.
MES and ERP technologies function as complementary systems. While an ERP consolidates all business processes into one system, an MES bridges the gap between your manufacturing operations and the ERP. This connection enables your MES to provide detailed insights into manufacturing processes, machinery, and workflows, enhancing the data richness and operational understanding within the ERP system.
How does an MES shop floor system work?
An MES connects machines, inventory systems, and workers to create a streamlined, real-time view of your entire manufacturing process. By centralizing data and automating workflows, it gives you the tools to operate more efficiently and make smarter decisions on the fly.
Here’s an overview of how MES shop floor systems work:
- The MES system pulls live data from machines and connected software so you always know what’s happening on the floor. This helps you identify issues early and eliminate delays.
- Tasks are automatically assigned based on factors like machine availability, operator capacity, and material readiness. Production flows smoothly with less manual input required.
- As parts are used, stock levels update in real time, triggering reorder points and preventing shortages or overproduction.
- When priorities shift, the MES adjusts the production schedule accordingly.
- If quality slips, the system flags the issue right away, allowing for quick intervention before problems spiral out of control.
- Everyone works from the same data, improving communication and enabling faster, more confident decision-making.
In other words, MESs make your shop floor run more intuitively and intelligently. Fishbowl Manufacturing brings this to life with built-in tools that simplify production planning, tighten inventory control, and keep manufacturing orders organized from start to finish.
Things to consider when choosing an MES software
The right MES looks different for each organization and sector, but the following factors remain universally important.
Business requirements
Begin by asking yourself what your specific MES needs are. List the must-have features followed by the nice-to-haves. If your manufacturing process relies heavily on real-time data, for instance, ensuring the MES can provide live updates is essential. This approach helps you eliminate platforms that don’t meet your essential criteria, narrowing your search to the most suitable options.
User-friendliness
Evaluate the system’s usability and learning curve. Arrange a demo and include decision-makers, C-suite executives, and end-users like floor managers and machine operators. If the system’s interface is intuitive and straightforward for the floor staff who’ll use it daily, it’s likely a good fit.
Scalability and flexibility
Look for solutions that can grow and adapt with your business, not just ones that meet your current needs. A cloud-based MES, for example, can quickly scale to accommodate increased production demands and new machinery without significant system overhauls, unlike more rigid on-premise solutions.
Integration capabilities
Examine how well the MES integrates with existing business technologies, looking especially closely at your ERP system. The ideal platform should seamlessly connect with all your key business technologies to streamline workflows.
Imagine you’re using a specific ERP for supply chain management. If your MES identifies a production bottleneck, it should instantly relay this information to your supply-chain-managing ERP. This lets the ERP quickly update order timelines, alert customer service for proactive outreach, and modify purchase orders as needed.
Manufacturing management made easy with Fishbowl
Maximizing production efficiency is essential for enhancing operational efficacy and profitability, and it doesn’t have to be challenging. Discover Fishbowl, the cloud-based inventory management system that simplifies your core business operations. Fishbowl integrates stock, warehouse, and sales operations into a single platform, providing real-time insights into every business aspect.
Further enhance your operations with Fishbowl Manufacturing, which seamlessly connects materials, workforce, and workflows across your manufacturing process. By centralizing these functions, Fishbowl Manufacturing removes the complexity of using multiple systems, offering a powerful tool for precise decision-making and increased agility in production processes.
