What are the Benefits of a Manufacturing Execution System?

Modern manufacturing organisations need an IT solution for their factories that will keep them future-proof in the era of the industrial Internet of Things (IIoT) rather than merely a manufacturing execution system. Modern digital factory monitoring eventually boosts competitiveness and site security; it is not an end in and of itself. This is a divergence from traditional MES and digitisation. For this reason, open platform solutions are becoming increasingly common in the industrial B2B sector, just like they are in the B2C sector.

Significant advancements in methods and means have not diminished the unpredictable and competitive nature of today’s production. So much so that, in order to survive, the average producer needs to do much more than employ the newest bells and whistles.

Manufacturers must be adaptable and continuously maximise efficiencies in order to raise output levels, boost quality, and increase profitability. It only takes the correct amount of visibility into crucial operations to do this, which calls for a thorough understanding of production. One essential component is an open MES platform with integrated MES features. With the use of precise shop floor data, it organises and digitises machine integration, plant maintenance, production and quality controls, and real-time analytics.

In order to obtain a competitive edge and stay in business, this leads to increased efficiency at lower costs, quicker decision-making, and larger profitability.

A Manufacturing Execution System (MES): What is it?

Mapping, tracking, and managing intricate production processes is the responsibility of a production Execution System (MES), a type of Manufacturing Management System. Ensuring the efficient execution of manufacturing processes and enhancing production performance are the primary goals of a manufacturing execution system (MES). It assists a business in achieving these objectives in this way. It accomplishes this by gathering and using precise, up-to-date data across the whole production process.

The phrase “Manufacturing Execution System,” or MES for short, refers to a functional category of automated systems that coordinate, record, and oversee the physical operations that convert raw materials into intermediate or final products in real-time. The objective is to increase production and product execution efficiency through the use of MES control and capabilities.

Manufacturing Execution Systems handle quality, inventory, and other critical aspects of the manufacturing process in addition to controlling hardware. These factors are usually taken care of by using MES software to integrate various operations.

These extensions are difficult to classify as components of conventional MESs. Rather, they are referred to as manufacturing operations management solutions, or MOM, by many experts in the MES sector. MES software, despite its technical nomenclature, is designed to facilitate production operations, report data, and give precise information about what is occurring on the shop floor.

What Are the Applications of Manufacturing Execution Systems?

Many different industries employ manufacturing execution systems, and a number of them are growing quickly, including consumer products, pharmaceuticals, food and beverage, industrial manufacturing, electronics and technology, and medical devices.

Production adapted to individual orders, discrete assembly, batch processing, rolling product manufacture, and more is made possible by manufacturing execution systems. They also enable complex process workflows. All aspects of production can benefit from an understanding of the basic principles of a MES. For example, a Materials Engineering System (MES) plays a crucial role in materials traceability, which is necessary for compliance in industries such as Food and Beverage, Medical Devices, and Aerospace. A superior MES may revitalise a manufacturing firm by optimising operations across the board, especially when combined with an ERP system for manufacturing.

Why are the features of MES crucial for businesses engaged in manufacturing?

Organisations may effectively monitor and optimise their manufacturing processes with the help of the MES features. Businesses may instantly match data from the ERP system with real-time manufacturing data, acting as a bridge between the operational management team and the process control level. Manufacturing transparency is now unheard of, thanks to this. Real-time insight into machinery and systems is another feature that allows for quick intervention in the event of issues or breakdowns.

Apart from its fundamental purposes, a manufacturing e-commerce system (MES) aids businesses in managing and conquering the massive obstacles provided by rules and policies from different sectors, like the aerospace or pharmaceutical industries, by providing product traceability.

Additionally, this may be applied to process manufacturing as well as discrete production for sectors including aerospace, defence, and automotive. The following are some of the main advantages that a manufacturing execution system provides:

• A higher level of client happiness
• better adherence to regulations
• A faster time to market and greater agility
• more visibility into the supplier chain
• shortened cycle time for manufacturing
• gotten rid of manual data entry and paperwork
• less time spent on orders
• Reduced labour expenses
• lower WIP inventory
• heightened use of machines

Thus, time, cost, and quality—the three main objectives—can all be attained with the use of a MES system.

Below are the benefits of establishing an MES system in place at your business.

Manufacturing Execution Systems Provide Network Functionalities

A manufacturing execution system is made to compile and keep track of production data for a factory. To make data collecting easier, an MES is networked and linked with equipment. Managers and controllers receive training on how to handle and support this data collection procedure. Lastly, the MES is integrated with corporate business applications to create a full system.

A manufacturing plant obtains complete transparency, control, and manufacturing optimisation as a result of this networking. Order placement, product development, process control, and production output are all phases that are tracked down and examined. Errors or malfunctions that are expensive in terms of time or money can be quickly found and fixed. Manufacturers of all sizes benefit immensely from this networking capacity in terms of efficiency and capacities.

Minimise Waste

A manufacturing facility can cut waste in several areas by using a manufacturing execution system. An MES is, first and foremost, a computerised system that includes electronic batch and device history records in addition to digital master logs. This implies that there is little to no need to keep paper copies of information in an office setting. Office time and expenses are no longer influenced by filing, storing, and time spent finding papers. Speaking about the time saved, back-office automation contributes to a reduction in data entering time when utilising an electronic data entry system.

The manufacturing plant is another crucial location for waste reduction. Because MES setups are standardised and optimised, they minimise scrap and material waste. The manufacturing process is stopped until the problem is fixed if a step in the process isn’t working properly, which the MES will identify in real-time. With the amount of product that may be produced incorrectly in a matter of hours, this is a significant cost-saver.

Enhance Work Efficiency

Accordingly, a manufacturing line’s as well as the front and back offices’ productivity can be greatly enhanced by an MES. There is less space for error and more chance for cooperation when everyone agrees. A manufacturing team’s whole membership stays informed thanks to a MES.

Think about the situation when a substance that is required for production is out of stock. Instead of wasting time contacting different people to find the information, it’s all stored in a system that’s available to all team members. This system documents everything, including properly maintained equipment, source inventory, and the appropriate tooling for a given project. Increasing productivity also means increasing uptime, and every manufacturing facility that wants to succeed needs to have high uptime.

Cut Down on Product and Material Stock

Inventory is one of the most expensive components of any manufacturing business. Maintaining and storing a large inventory comes at a cost. Then, there is the factor of supply and demand, which can raise or lower an inventory’s value. This can distort the total value of your business depending on the market value of your inventory, whether it is filled with raw materials or completed goods. However, in order for your business to continue operating, a specific level of inventory is required.

How do producers strike a balance on this? To begin, they cut back on the quantity of goods kept on hand as a backup plan. Manufacturers can have confidence in the number of raw materials and completed goods required for the next few years by utilising an MES system. In addition, a manufacturing facility can reduce excess inventory by using an MES to track and document shipping and purchases.

Production managers will no longer have to frantically search for supplies to maintain assembly lines operating or to use in an emergency. As an alternative, the business will keep the required stock levels in check in accordance with production requirements and emergency runs. Because everyone will have what they need to finish their work without difficulty, employee satisfaction and client service will soar.

Wrapping Up

From an efficiency and profitability standpoint, MES systems are incredibly advantageous. Manufacturers are shifting to a digitally-based production execution system, nevertheless, for another reason. All people are getting digital in this day and age. An MES is rapidly becoming a crucial component of any plant’s operations in order for manufacturers to stay up-to-date and connect with shippers, customers, and logistics.

Manufacturing operations can be complex and challenging but extremely rewarding when targets are successfully met. Skilled operators, leaders and managers working together will help you to achieve the strategic aims of your business. Find out how IoSCM can equip your team with the knowledge, confidence and skills they need to succeed. Call 0800 1422 522 today.