What is an MES system?
MES (Manufacturing Executing System) is a program for managing production and monitoring production processes based on real-time data. MES can be integrated with machines, allowing the software to automatically retrieve production data. This enables ongoing optimization and rapid response to deviations.
Who is MES software for?
MES software is designed for manufacturing companies that want to:
- integrate the production management system with machines and other warehouse and logistics software;
- integrate all operational activities in the production area;
- improve and accelerate the planning, scheduling, production, control and reporting processes;
- eliminate errors and avoid costly downtime;
- increase the efficiency of employees and devices;
- reduce operating costs;
- achieve higher quality indicators;
- increase production competitiveness in the market;
- increase the level of safety and comfort of production department employees.
How does the MES system work?
An MES system works by collecting data about production processes, which is then processed and reported in real time. This enables quick decision-making and immediate response to any production deviations.
What data does the MES program collect?
MES collects key information about machine operation, including whether they are working properly and identifying the causes of downtime. The application records work time allocated to specific orders and production operations, enabling precise performance monitoring. Specifically, this data includes: 
- duration of the operation,
- ilości wyprodukowanych wyrobów,
- product quality,
- time and causes of downtime,
- consumption of raw materials
- machine efficiency,
Thus, the MES program enables:
- calculating the OEE (Overall Equipment Effectiveness) index,
- production optimization through detailed data analysis,
- identification and elimination of bottlenecks,
- improving operational efficiency.
What are the main functions of the MES system?
- Production Order Management: Vendo MES allows you to assign tasks and track the progress of each production order from start to finish. This allows you to increase efficiency in meeting production schedules and respond to deviations.
- Ongoing tracking and documentation of the production process, i.e. the system enables precise monitoring of each stage of production, recording data on working time, work progress, and the use of raw materials in real time.
- Quality Management – MES monitors product quality parameters in real time. This allows for the rapid detection of defects and thus prevents the production of defective products.
- Monitoring the efficiency of machines and employees – by collecting information about the actual time spent working on a task, the system compares it with the assumed standards, calculating the efficiency of employees and machines.
- Analysis and Reporting – Knowing the current production status allows for the presentation of real-time information about the current state of machinery, employee activity, and order fulfillment. Historical data analysis enables the calculation of OEE metrics, downtime and breakdown times, and tracking the actual costs of production orders.
What does working on an MES system look like?
Working with the Vendo MES system begins with the operator downloading a task scheduled for a given hour through the planning module (Alice APS) on the production panel. The MES software records:
- start time of work,
- machine changeover or setup time,
- machine speed (clock speed, number of meters per minute),
- used raw materials,
- downtime and its causes,
- product parameters and key machine operating parameters.
If the MES system is connected to machine controllers and sensors, it automatically collects some, if not all, of this information. In practice, the software typically automatically records data on machine start and stop times, work rate, and the start and end of downtime. Once a task is completed, the operator downloads the next task, continuing the production cycle. This allows for smooth production flow and immediate response to any disruptions.
How does the MES system integrate with machines?
The MES system integrates with machines to automate the collection of data related to the production process. This reduces the burden on production workers from manual input and completely eliminates errors.
The method of integrating Vendo MES with a machine depends on the type and modernity of the machine.
- The latest machines are based on modern controllers, and therefore equipped with features enabling data exchange with other programs. This simplifies integration and relies on standard protocols.
- Older machines connect to the system via sensors installed on them. In short, they receive signals indicating whether and at what speed the machine is operating. The MES collects and interprets these signals. However, this requires matching and connecting the appropriate sensor to the machine, complicating the implementation process.
MES and ERP
One of the most important aspects of MES implementation is its interaction with ERP.
Both systems from one supplier
The MES system, as a module within Vendo.ERP, ensures data and process consistency across the entire organization. This ensures all information is available in one place, simplifying management and reporting. Implementing a system from a single vendor within a single platform is less expensive and time-consuming compared to integrating two separate applications. Using Vendo software also simplifies the implementation and management process, leading to greater operational efficiency and lower costs.
MES as separate software
Choosing the best MES software available, regardless of the ERP vendor, allows for solutions tailored to the company’s specific manufacturing needs. Furthermore, a standalone MES can be more easily scaled and updated without impacting other management systems, providing greater flexibility and adaptability to changing production requirements. However, this comes with the cost and potential challenges of integrating these two tools.
What data is exchanged between MES and ERP?
Collaboration between production management programs requires the exchange of various data, which allows for the synchronization of processes and resource management. Here’s how these two systems work together:
In simple terms, ERP sends a queue of production tasks to the MES program. Specifically, these include production schedules, order lists, and detailed instructions for completing individual tasks.
The MES reports the current status of production orders to Vendo, providing information on work progress, completed operations, and any delays. It also provides information on the quantities of raw materials used, which enables the ERP software to manage inventory and plan supplies. Data on the quality of manufactured products allows for monitoring quality indicators and identifying defective batches. Information on machine operating times and employee operations is transferred to the ERP, enabling the calculation of production costs and operational efficiency. Integrating Vendo with the MES supports comprehensive production management and process optimization.
MES implementation – challenges
- Integration with Legacy Machines – Legacy machines often require additional sensors to capture operational data. This process can be complex and time-consuming, requiring precise matching of the appropriate sensors to the specific machine.
- Additional API costs – Modern machines are equipped with APIs (application programming interfaces) enabling communication with the MES application. However, access to the API may involve additional fees, increasing implementation costs.
- Integration with other manufacturing management systems – MES software connects with other systems, such as ERP and APS. This integration can be complex and requires extensive configuration and testing to ensure a smooth data flow.
- Necessity of installing panels on the shop floor – Implementing MES often requires installing terminals or panels on the shop floor for employees to use. This process can involve additional hardware and installation costs.
- Potential Staff Resistance – Employees may be resistant to new software, especially if they are accustomed to traditional work methods. Training and demonstrating the benefits may be necessary to reduce this resistance and encourage active use of the system.
- Adapting to specific company needs – Every manufacturing company has its own unique processes and requirements. Adapting the program to these specific needs can be a challenge, requiring additional configuration and customization.
What benefits does the MES system provide in production management?
Improved employee performance – MES Vendo monitors individual and group employee performance, which can lead to improved work efficiency by up to 10-30% by identifying areas requiring correction and optimizing operations.
Better machine utilization – The program ensures better machine utilization (improved OEE), which can increase their utilization and efficiency by up to 15-35% through constant supervision of their operation and elimination of unplanned downtime.
Reduce unplanned downtime – Downtime notifications and root cause analysis can reduce unplanned downtime by up to 15-30%, allowing for quick corrective action.
Shortened production cycle – MES can contribute to shortening the production cycle by 10-20% thanks to better utilization of existing production capacity and reduction of unproductive machine downtime.
Control of actual product costs – Vendo enables accurate tracking of the actual working time of machines and people, which allows for a more precise calculation of the technical cost of manufacturing a product.
Increased quality – MES monitors and controls product quality parameters, which can lead to a 5%-20% reduction in defective products, increasing overall product quality.
In summary, thanks to MES, companies can improve their efficiency, quality and control over production processes, which translates into increased competitiveness and profitability of their operations.
