What is a Manufacturing Execution Systems and Software (MES)?
A Manufacturing Execution System (Manufacturing Execution Systems and Software) refers to computerized systems used within production and manufacturing operations to track and document the transformation of raw materials to finished goods. Manufacturing Execution Systems and Software provides information that helps optimize production processes in real-time by capturing and communicating data between the shop floor and other areas of a production facility or plant.
Manufacturing Execution Systems and Software Software Applications
Manufacturing Execution Systems and Software software solutions are deployed to monitor, collect, and process real-time data from the manufacturing equipment on the plant floor level for various applications. Some common Manufacturing Execution Systems and Software applications include:
Production Tracking and Order Management
Manufacturing Execution Systems and Software allows manufacturers to track production schedules, releases, required materials, labor hours and other parameters against planned orders. Production supervisors can view current order status, remaining quantities, expected finish times on dashboards.
Labor Tracking and Allocation
Manufacturing Execution Systems and Software captures operator logins, workstation assignments, labor hours spent on jobs. This data helps manage employee performance and labor costs. It facilitates optimal allocation of operators across work centers based on current demand.
Quality Management
Quality parameters like dimension checks, weight measurements, functional testing results etc. can be captured electronically via Manufacturing Execution Systems and Software connected sensors and inspection devices. Non-conforming products can be put on hold for rework. Quality reports aid in continuous improvements.
Equipment Data Collection
Manufacturing Execution Systems and Software collects operational data from plant floor machines for OEE (Overall Equipment Effectiveness) measurement and predictive maintenance. Down periods, downtime reasons, changeovers are tracked. Equipment performance bottlenecks can be addressed.
Document and Manufacturing Execution Systems and Software (Manufacturing Execution Systems and Software)
Manufacturing Execution Systems and Software ensures associated documents, work instructions and materials required for production are available. It manages material requests, issues, returns and inventory levels in real-time. This aids JIT (Just-In-Time) manufacturing.
Integration With Other Systems
Manufacturing Execution Systems and Software offers interfaces to ERP systems for efficient transfer of production and order data between front-end and back-end applications. It can also integrate with historian systems to archive long-term equipment and process data for analyses.
Key Benefits of Manufacturing Execution Systems and Software
Manufacturing Execution Systems and Software deployments help manufacturing organizations achieve several operational and strategic benefits:
Increased Overall Equipment Effectiveness
By optimizing changeover processes, reducing downtime reasons through preventive actions, manufacturers can boost productivity significantly.
Improved Quality and Consistency
Real-time quality monitoring ensures defects are minimized. Consistent processes lead to uniform product quality overtime.
Effective Capacity Management
Manufacturing Execution Systems and Software gives current performance visibility to balance workload across lines/shifts based on labor/equipment availability. It prevents bottlenecks.
Reduced WIP and Work-in-Progress Inventory
Integrated material tracking eliminates overproduction through JIT pull systems. Lower WIP translates to higher inventory turns.
Energized Decision Making
Actionable plant-level data and analytics available right at the decision maker’s fingertips facilitate better short-term and long-term decision making.
Streamlined Compliance Management
Manufacturing Execution Systems and Software improves compliances to quality/production standards through automatic workflows, electronic approvals and signatures trail.
Customized Reporting and KPI Tracking
Key performance metrics across all departments can be monitored using pre-built or ad-hoc reports from a unified data source. Corrective measures can be implemented in a timely manner.
Manufacturing Execution Systems and Software Architecture
Manufacturing Execution Systems and Software solutions operate on a layered architecture design at three levels – the plant floor, manufacturing operations and management. Manufacturing Execution Systems and Software software components reside across these architectural layers:
Plant Floor Layer
Data collection servers, plant floor servers acquire real-time data from ERP systems, plant floor equipment via OPC/OLE for Process Control communications.
Manufacturing Operations Layer
Manufacturing Execution Systems and Software application servers connected to plant floor data collection servers consolidate, analyze and organize production data for use by operations. It contains production scheduling, execution management modules.
Management Layer
Manufacturing Execution Systems and Software web-based portals, reporting interfaces connected to application servers provide intuitive access to production performance metrics, reports to managers. Business Intelligence tools draw analytical insights here.
Manufacturing Execution Systems and Software Implementation Considerations
Manufacturing Execution Systems and Software solutions involve robust programming and configuration to fully leverage the software capabilities. Thorough system validation testing must be performed prior to going live with Manufacturing Execution Systems and Software. Buy-in from plant employees is crucial for adoption. Organizations must factor the following while implementing Manufacturing Execution Systems and Software:
- Align implementation with strategic production KPI targets
- Choose a scalable solution matching current/future requirements
- Ensure equipment connectivity – obtain equipment/sensor data via OPC, APIs
- Train employees on new interfaces, processes and KPI parameters
- Integrate workflows seamlessly with existing ERP for transactional data flow
- Get executive buy-in and sponsorship for change management efforts
- Continuously measure and improve KPIs to demonstrate ROI to stakeholders
In summary, Manufacturing Execution Systems power real-time shop floor visibility and controls for manufacturers worldwide to streamline operations, boost quality consistency and optimize productivity across plants. Manufacturing Execution Systems and Software implemented hand-in-hand with strategic capacity planning assists organizations achieve enhanced manufacturing competitiveness.
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Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)
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