MES (Manufacturing Execution System): passing fad or real revolution?
In recent years the term MES has become ubiquitous in the vocabulary of the manufacturing industry. For some, it’s just another buzzword; for others, the lever to truly move toward a data-driven factory. Where does the truth lie? In this article we look at what an MES is, what it really does (and what it doesn’t do), the benefits it brings, and how to tell whether it’s the right time for your company to adopt one.
What is an MES, in simple terms
A Manufacturing Execution System is the information system that connects planning (ERP, MRP) with actual execution on the shop floor, synchronizing people, machines, materials, and quality. It collects real-time data, guides operators through processes, and returns indicators that help you make decisions here and now.
What a MES typically does
End-to-end lot/serial traceability
Machine (times, scrap, downtime) and operator data collection
Order progress, time and material actuals
Recipe, parameter, and process version management
In-process quality control (SPC, nonconformities, corrective actions)
Basic preventive/condition-based maintenance (if integrated)
OEE dashboards and efficiency KPIs
What it is not (and what not to confuse it with)
ERP: plans and accounts for, but does not orchestrate minute-by-minute execution.
SCADA/PLC: read from and control machines; the MES uses these data to govern the production flow.
PLM: manages the product lifecycle; the MES deals with how it is manufactured today, shift by shift.
Why it’s such a hot topic today
Three forces are accelerating interest:
Volatile demand and smaller lots: you need responsiveness, not just average efficiency.
Pressure on quality and compliance: you need certain, audit-ready traceability.
Technology maturity: sensors, OPC UA, APIs, edge and cloud make real time economically accessible.
Measurable benefits (beyond the rhetoric)
A well-implemented MES is not a “nice little report.” Typical outcomes include:
OEE ↑: fewer micro-stops and faster changeovers thanks to guided setups and root-cause analysis.
Scrap ↓: in-process checks and statistical limits prevent quality drift.
Lead time ↓: visibility of progress and dynamic reassignment of resources.
Instant traceability: selective recalls, faster and cheaper audits.
Cost accuracy ↑: actual times and consumptions replace outdated standards.
Data-driven culture: from “we’ve always done it this way” to decisions backed by facts.
Note: actual figures depend on your starting level, mix, and operational discipline. How you implement matters as much as what you buy.
Fad or revolution? Integration is the key
MES becomes revolutionary when it integrates process, people, and technologies:
With ERP: up-to-date orders and master data → reliable actuals and a more realistic MRP.
With machines/SCADA: real field data → reliable KPIs, not “filled in at end of shift.”
With quality and the lab: closing the CAPA loop → prevention, not just inspection.
With maintenance: from reactive to preventive/condition-based, reducing critical stoppages.
Without integration, MES risks becoming just another silo: fad, not revolution.
Cloud or on-premise?
Cloud: quick start, lower upfront costs, scalability; requires attention to latency, connectivity, and security.
On-premise/edge: maximum control, low latency with legacy machines; higher IT investment and management.
Hybrid: execution logic near the machines (edge), analytics and historical storage in the cloud.
How to implement it (without the pain)
Define business KPIs before technical requirements (e.g., OEE +5 pts, scrap −20%).
Select high-impact pilot processes with a strong sponsor.
Connect a few machines well (open standards, clean tags) rather than many “so-so.”
Design the data: unique codifications, recipe versioning, exception handling.
Change behaviors: train operators, clarify roles, visible feedback loops on the shop floor.
Incremental releases: short sprints, retrospectives, and hardening before scaling.
Governance and cybersecurity: personal accounts, OT/IT network segregation, tested backups.
Common mistakes to avoid
Implementing everything at once (big bang), wasting momentum and budget.
Chasing extreme customization where a standard already covers 80%.
Neglecting master data and codifications: garbage in, garbage out.
Measuring only “go-live” instead of capturing benefits with tracked KPIs.
Ignoring the operators’ voice: the MES must make work easier, not add bureaucracy.
Which MES functions do you really need? (practical priorities)
NeedKey MES functionsWhy nowVisibility and timingOrder progress, dispatching, digital andonsReduce delays and work-in-queueEfficiency and costsDowntime collection, OEE, cycle timesIdentify bottlenecks with objective dataQuality and complianceSPC, control plans, genealogyAudit-ready and less scrapMaterial traceabilityLots/serials, Genealogy, eDHR/eBRTargeted recalls and customer trustMix/variant flexibilityRecipe, parameter, version managementFaster, safer changeovers
Readiness checklist (5 minutes)
KPIs and business case defined and shared
Operational and IT sponsors identified
Machines with known interfaces (OPC UA/MQTT/drivers)
Master data (items, BOMs, routings) 90%+ reliable
Documented quality processes
Training plan for shift leaders and operators
Budget for change management, not just licenses
If you tick at least 5–6 boxes, you’re close to a true revolution; otherwise, start with data readiness and standardization.
Frequently asked questions (FAQ)
How long does it take to see benefits?
With a well-targeted pilot, the first reductions in downtime/scrap show up 8–12 weeks after the pilot area’s go-live.
Do we need IIoT/Industry 4.0?
No, but machine connectivity and data standards multiply MES value.
What if our machines are old?
Gateways/edge devices and sensor retrofits can bridge the gaps at accessible costs.
Will MES replace ERP?
No. ERP and MES are complementary: the former plans and accounts, the latter executes and optimizes.
Conclusion: not a fad, but a conditional revolution
MES is neither a magic wand nor a passing fad. It’s an enabler: it can transform how you manufacture only if it’s part of a clear vision, integrated with ERP and machines, and accompanied by operational discipline. Where these elements exist, the results are structural and defensible.
Want to understand how much an MES could impact your departments (and where to start to maximize ROI)?
Contact us for a free, no-obligation demo at info@metalya.it.