Understanding Manufacturing Execution Systems (MES)
Manufacturing Execution Systems (MES) are software solutions intended to sustain efficient manufacturing processes to produce high-quality products. Manufacturing execution systems can connect the various levels of the manufacturing process, including multiple plants, manufacturing sites, and vendor production. Within each of these locations, MES software can also connect with manufacturing equipment, Industrial Internet of Things (IIoT) sensors, and supplemental enterprise software solutions.
Custom manufacturing software can bring additional value to a company’s operations. Being able to manage multiple locations and heavy equipment within one software solution allows companies valuable insight into their manufacturing operation. With this insight, companies can improve production efficiency, strengthen security control, and reduce waste.
Essential Features of MES
According to the MESA-11 model, there are 11 core functions of the manufacturing execution system. While the functions have evolved since they were first established in 1997, the original 11 functions still provide the base layer for most MES solutions.
1. Labor Management: Manage employee time data, qualifications, and authorizations to improve labor management. This allows management to track employee schedules and manage business operations requirements quickly and easily.
2. Quality Management: Having an effective quality management process will allow your company to improve production value. This function can identify and track quality deviations and exceptions, improving overall quality control.
3. Operations Management: This function allows employees to get a full-picture view of the production process, including an outlook of planned orders and the routing plan. This allows your employees to understand the plan, get on the same page, and reduce the amount of errors from miscommunication.
4. Maintenance Management: By integrating equipment management functions into a MES system, companies can track work orders and machine health with sensors and IIoT technology. This allows management to schedule preventative maintenance, improving equipment effectiveness without disrupting production.
5. Process Management: Effectively manage the production process from start to finish, getting valuable insight into production rates and bottlenecks. This allows management to optimize processes to improve quality while allowing complete production traceability.
6. Performance Analysis: Process data to calculate key performance indicators (KPIs), identify strengths and weaknesses, and determine changes that could positively impact operations. Being able to measure growth and success accurately is an essential function for management to have data backing up their progress.
7. Resource Allocation and Status: Take advantage of real-time data to identify and track the company’s inventory levels, including labor, industrial machinery, and materials. This data allows management to allocate resources to reduce waste and maximize utilization.
8. Product Tracking and Genealogy: Being able to track the product’s complete history, including materials and assembly, allows manufacturers to make informed decisions for their company. This is especially useful for manufacturers who must follow regulatory compliance guidelines.
9. Data Collection and Acquisition: Collect and analyze real-time manufacturing data from the production lines, manufacturing operations, and production processes to make well-informed decisions. Having this data readily available can help management improve processes and efficiency.
10. Dispatching Production Units: Easily manage the real-time production cycle data to make quick, calculated adjustments to production operations. Being able to access real-time product data ensures calculations are accurate and up-to-date.
11. Document Control: With how much work these days is managed digitally, it makes sense to manage all documents within a MES system. These documents can include schedules, notes, instructions, and process guidelines. Having them available to all users means nothing slips through the cracks or gets lost in a filing cabinet.
The Role of MES in Production Control
A manufacturing execution system allows companies to get a visual representation of the manufacturing and production processes, distribute instructions to employees, and gather production data that can improve quality control. Having this broad, valuable insight into the production control systems gives companies the information needed to make meaningful changes to the production process.
How MES Can Enhance Your Manufacturing Efficiency
Manufacturing execution systems are beneficial for many reasons, but one is the ability to improve manufacturing efficiency. Here are a few ways companies can improve efficiency with the data collected by manufacturing execution systems.
Streamlining Operations with MES
One beneficial function of manufacturing execution systems is the ability to gather and analyze real-time and historical data of various operations and processes. This data can help management identify bottlenecks, pain points, and inefficiencies in manufacturing operations management. With this knowledge, companies can make gradual and meaningful changes to their operations and use real-time data to confirm if the changes positively impacted the operations process.
Enhancing Transparency and Data Accuracy with MES
Manufacturing execution systems are built to collect data from machines, sensors, and various operations processes. Having a system collect this data in real time improves the accuracy of this data by minimizing the chance of human error. Companies can also improve data transparency by gathering data throughout the manufacturing process and making this information available to a wide range of users.
The Benefits of Integrating MES with Other Business Systems
One of the most common systems integrated with MES is the Enterprise Resource Planning (ERP) system. ERP systems are cloud solutions that companies use to manage their daily work, including project management, supply chain management, accounting, and risk management. It’s common for a company to integrate an ERP system with its manufacturing execution system as it provides a complete view of its manufacturing and business operations.
Practical Steps to Maximize Efficiency with Manufacturing Execution Systems
Manufacturing execution systems are designed to improve operations and make processes more efficient, but this result isn’t a guarantee. Consider the following steps to ensure employees are effectively utilizing the manufacturing execution system.
Employee Training and Change Management
Have complete and effective employee training sessions to encourage the proper use of the MES solution. Change to processes and systems can be a challenge to implement, as many employees are often comfortable with what they already know. By making sure everyone is trained and comfortable with the manufacturing execution system, employees are more likely to use it efficiently.
Monitoring and Continuous Improvement with MES
Monitoring employees’ use of the MES systems can allow companies to identify which functions are utilized most. Some functions that sounded beneficial during the software development process might actually be inefficient for the employees who use the system daily.
To keep the manufacturing execution system as a valuable resource for employees, regularly ask for feedback on the system. This will allow the company to see where improvements can be made and any additional functions that could be added.
Work With Geneca Today
Manufacturing execution systems can give your company control over your operations and valuable insight into your processes. Contact Geneca today to discover how to optimize production and workflows with manufacturing execution systems.
