MES Manufacturing Execution System

A MES (Manufacturing Execution System) is software that manages and monitors production processes in real time. It serves to: track the progress of production orders phase by phase, detect processing times and machine downtime, manage quality and waste, connect operators and materials to orders. MES bridges the gap between strategic ERP planning and operational execution, providing complete visibility into what is happening in production momeA MES (Manufacturing Execution System) is software that manages and monitors production processes in real time. It serves to: track the progress of production orders phase by phase, detect processing times and machine downtime, manage quality and waste, connect operators and materials to orders. The MES bridges the gap between ERP strategic planning and operational execution, providing complete visibility into what is happening in production moment by moment by moment.

MES solves critical manufacturing problems: lack of real-time visibility into the status of orders and advances, replacing manual management on paper or Excel with errors and duplication, difficulty tracking batches and ensuring product traceability, inability to calculate actual production costs and OEE, and information delays that arrive too late to intervene. With MES, all production processes are digitized, eliminating paper and obtaining precise data for continuous improvement.

The cost of a MES varies according to: number of lines/machines to be connected, active users, necessary modules (advancement, quality, maintenance), required integrations with ERP and machinery. For small to medium-sized companies, prices start at 15,000-30,000€ for basic solutions, up to 50,000-150,000€ for full implementations. Implementation times range from 3-4 months for standard projects to 6-12 months for complex multi-site realities. The average ROI is reached in 12-24 months.

The core features of a modern MES include: production order management, production progress with machine and labor time tracking, material and batch traceability with barcodes/RFID, inline quality control with defect and non-compliance recording, resource management (operators, equipment, materials), performance analysis with KPIs such as OEE, Takt Time, Lead Time. Two-way integration with ERP closes the production-management information cycle.

MES can function as a stand-alone system to manage production, but integration with ERP is strongly recommended to achieve maximum value. The ERP sends production orders, bills of materials, duty cycles and stock to the MES, while the MES returns to the ERP advances, material consumption, finished product discharges and production data for industrial accounting. Without integration, the benefits of automation are lost and there is a risk of data duplication.

To choose the right MES, evaluate these criteria: ease of use for department operators (intuitive touch-screen interfaces), flexibility and customization on your specific production processes, integration capabilities with your existing ERP and machinery, modules available as needed, supplier experience in your industry, and quality of support throughout the digital transition of your production.