Developing Custom Manufacturing Execution System (MES) for Enhanced Production Control

In today's fast-paced manufacturing environment, optimizing production control is crucial. One of our clients, a leading thermosensor manufacturer, wanted to bridge the gap between their existing ERP system and the real-time demands of their production floor. By integrating a custom Manufacturing Execution System (MES), we provided the necessary granularity, enabling them to monitor production in real time and streamline operations, resulting in enhanced efficiency and control.

In this blog, we will explore how integrating a custom Manufacturing execution system with an existing ERP system helped a manufacturing company improve its production efficiency and enhance control, ultimately leading to significant operational gains.

Challenges Faced Before MES Integration

Before MES integration, the company depended solely on its SAP ERP for production management, which faced limitations due to the complexity of managing multiple production units.

1. Lack of Real-Time Production Visibility: The ERP system could not provide a consolidated production view, leading to delays in decision-making.

2. Inefficient Resource Utilization: The company faced difficulties in optimizing machine and workforce usage due to the lack of real-time insights into resource availability and performance.

3. Disjointed Communication: Fragmented systems resulted in poor communication between production, quality control, and team management, delaying issue resolution.

4. Reactive Quality Control: Quality checks were performed too late in the production process, and stage completion oversights further increased rework costs and delayed delivery times.

Solution: Custom MES Integration with ERP for Enhanced Production

To address the challenges faced by the company, integrating a custom Manufacturing Execution System (MES) with their existing ERP system became essential. Here are the key solutions provided by the MES integration:

Key components of the MES solution included:

1. Improved Real-Time Production Visibility: MES provides a real-time dashboard view of all production stages and resources, ensuring continuous tracking and proactive decision-making.

2. Efficient resource utilization: MES streamlines resource management by tracking supervisor workload, and material usage, reducing downtime and overuse.

3. Streamlined communication: MES centralizes communication by offering a unified view of production, improving coordination and preventing delays or miscommunication.

4. In-line Quality Checks: MES integrates real-time quality checks at each stage, allowing proactive issue detection and enforcing SOPs to maintain consistent product quality.

Advantages of MES Integration

The integration of the MES with the company’s ERP system delivered substantial improvements across their production operations:

1. Consolidated Production View: Provides a unified view of production processes across all units, streamlining management and making it easier to track multiple orders simultaneously.

2. Improved Resource Utilization: With detailed insights into labor availability, the company could better allocate resources, leading to more efficient operations.

3. Standardized Procedures Across Units: Creates SOPs for all types of orders, ensuring uniform processes across multiple production units for better control and efficiency.

4. Improved Interdepartmental Communication: The MES streamlined communication between production, quality control, and team management, improving the coordination of activities and minimizing production delays.

5. Real-Time Production Monitoring: Provides up-to-date visibility into all production units, enabling faster, more informed decision-making.

Conclusion: A Remarkable Boost in Efficiency

After successfully integrating the Manufacturing Execution System (MES) with their existing ERP system, the company reported remarkable improvements. The client provided us with feedback that, “This integration has revolutionized our production management. We’ve seen a 40% increase in operational efficiency, thanks to the seamless real-time tracking and resource optimization provided by the MES.”

The results of the integration speak for themselves, highlighting the importance of combining ERP systems with MES for enhanced production control. If your company is looking to boost efficiency and gain better control over your production processes, WEBaniX Solutions can help design and implement a customized MES tailored to your needs.

​Contact us today to learn how we can help optimize your manufacturing operations and drive performance improvements.