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How do you implement MES effectively and avoid common pitfalls and risks?

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Industrial IoT and smart manufacturing are transforming the way products are designed, produced, and delivered. But to achieve the benefits of these technologies, you need a robust and reliable manufacturing execution system (MES) that can integrate data, processes, and resources across your factory floor. How do you implement MES effectively and avoid common pitfalls and risks? In this article, we'll share some best practices and tips to help you optimize your MES strategy and performance.

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Anil Rajera, MBA

MES Consultant at GE Vernova| GE Proficy MES | vmware | MSSQL
John Knutson

Digital Transformation Leader

1 Define your MES goals and scope

Before you start implementing MES, you need to have a clear vision of what you want to achieve and how you will measure your success. Do you want to improve quality, efficiency, productivity, or customer satisfaction? Do you want to reduce waste, downtime, or defects? Do you want to comply with industry standards or regulations? Do you want to leverage data analytics or machine learning? These are some of the questions you need to answer to define your MES goals and scope. You also need to identify the key stakeholders, processes, and systems that will be involved or affected by MES.

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John Knutson

Digital Transformation Leader
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Many companies that delve into digital manufacturing want it all and it becomes hard to separate wish-list items from the work actually needed to meet the goals. When a company sets out to define goals and scope, I would encourage them to consider implementing a single production line/area first and to do so with a minimum of customization. Get your feet wet and learn the system and its capabilities and growth will accelerate.

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Anil Rajera, MBA

MES Consultant at GE Vernova| GE Proficy MES | vmware | MSSQL
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"In addition to that, another goal should be to standardize the process of collecting data fromPLC to SAP. For example, if there is an upgrade planned for the MES applications, then the configuration should be in a standard format so that the upgrade process can be easily automated, reducing production plant downtime

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2 Choose the right MES solution and vendor

There are many MES solutions and vendors in the market, but not all of them are suitable for your specific needs and context. You need to do your research and compare the features, functionalities, costs, and benefits of different options. You also need to consider the compatibility, scalability, security, and flexibility of the MES solution and vendor. You want a solution that can integrate seamlessly with your existing infrastructure and systems, that can grow and adapt with your business, that can protect your data and assets, and that can offer customization and support.

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Anil Rajera, MBA

MES Consultant at GE Vernova| GE Proficy MES | vmware | MSSQL
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The selection of a Manufacturing Execution System (MES) should be based on the specific products and processes of the industry. Understanding the production line architecture and data flow from Programmable Logic Controllers (PLCs) to MES or SAP is crucial. It is also important to identify the Key Performance Indicators (KPIs) and required reports for daily operations. The selection of an MES should align with the future vision of the company, aiming for standardization and automation to reduce downtime, waste, and rejects and improve Overall Equipment Effectiveness (OEE) for the plant.

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John Knutson

Digital Transformation Leader
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Just as important as MES solution selection, a good implementation partner can make all the difference in the success of an implementation. MES software is not an off-the-shelf product that you can install like an Office Productivity application. Production resources and processes need to be modeled and integrations need to be configured or developed. Find a services provider that has experience with one more more MES solution that is on your shortlist. Engage them for discovery and assistance in evaluation. The time spent up front on finding the right solution and partners will pay back in a smooth implementation. You may not realize the money and frustration saved unless you have been through an ill-prepared implementation before.

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3 Plan and execute your MES project

Once you have selected your MES solution and vendor, you need to plan and execute your project carefully and systematically. You need to establish a project team, a timeline, a budget, a communication plan, and a risk management plan. You need to follow the best practices and methodologies for project management, such as agile, waterfall, or hybrid. You need to involve and engage your end-users, managers, and other stakeholders throughout the project lifecycle. You need to test, validate, and verify your MES solution before going live.

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John Knutson

Digital Transformation Leader
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When you get to the planning stage it could be beneficial to consider implementation of one production line/area first and then expand to additional lines/areas for further phases of the project. A good implementation partner can help you achieve success with minimal downtime and teach you how to grow to incorporate new processes. After help with a few such step-wise implementations, you may be able to cut costs and implement new processes without external service providers. For those wanting to get it all done in one shot, plan, prepare, test, test and test some more. Leave yourself enough time and budget to ensure the system will work as expected and incorporate all your hidden processes. Prepare and involve your shopfloor for success

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4 Train and empower your MES users

One of the most critical factors for MES success is the adoption and usage of the system by your employees. You need to train and empower your MES users to ensure they understand the benefits, features, and functionalities of the system. You need to provide them with adequate resources, guidance, and support to help them use the system effectively and efficiently. You need to solicit their feedback and suggestions to improve the system and address any issues or challenges. You need to create a culture of continuous learning and improvement around MES.

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5 Monitor and optimize your MES performance

After you have implemented and launched your MES solution, you need to monitor and optimize its performance regularly. You need to track and measure the key performance indicators (KPIs) and metrics that align with your MES goals and scope. You need to analyze the data and insights generated by the system to identify the strengths, weaknesses, opportunities, and threats of your MES strategy and performance. You need to implement corrective and preventive actions to resolve any problems or gaps. You need to update and upgrade your system as needed to keep up with the changing demands and expectations of your customers and market.

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How do you implement MES effectively and avoid common pitfalls and risks?

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2

3

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1 Define your MES goals and scope

2 Choose the right MES solution and vendor

3 Plan and execute your MES project

4 Train and empower your MES users

5 Monitor and optimize your MES performance

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