Christian Méndez

What is an MES platform? Manufacturing Execution Systems, better known as MES (Manufacturing Execution Systems), represent a fundamental piece in the automation and optimization of processes in modern industry. These systems, designed to manage and monitor production in real time, have evolved over time, adapting to the changing demands of industry and technology. Origins and evolution of MES systems MES platforms have their origins in the 1980s, when industry began to realize the need for greater control and visibility into its production processes. With the introduction of computerized systems on the shop floor came the opportunity to optimize manufacturing management. Since then, MES platforms have evolved from simple production tracking tools to highly integrated and sophisticated solutions that address multiple aspects of the industrial operation. Hence, they are increasingly known as multidisciplinary tools that cover aspects of high added value. MES is a software tool that allows the planning, monitoring and control of production processes in factories in order to improve efficiency and quality and reduce costs. What are the main functionalities of an MES platform? One of the advantages of MES systems is that they are modular. This means that depending on the way each customer works and according to their specific needs, the MES solution required for each case is configured. Some of the most demanded: Collect real-time data from various sources on the shop floor, such as machines, sensors, automation systems and operators. This provides an accurate view of production status. Schedule and sequence work orders efficiently, taking into account factors such as resource availability, machine capacity and lead times. Manage inventory of raw materials, semi-finished products, and finished goods, ensuring that levels are optimal and avoiding shortages or overstocks. Track and trace products and components in the manufacturing process, essential to meet quality standards and regulations and manage product recalls if necessary. Integrate quality control systems, such as machine vision inspection, parameter measurement and quality data collection to ensure that products meet quality standards. Monitor and control manufacturing processes, adjusting process variables in real time to optimize production and avoid deviations. Assist in scheduling preventive maintenance of manufacturing machines and equipment, minimizing unplanned downtime. Generate detailed reports and analysis on production performance, efficiency, costs, quality, and other key performance indicators (KPIs), enabling data-driven decision making. Facilitate communication and collaboration between different plant teams, improving coordination and efficiency. Often integrate with other enterprise systems, such as enterprise resource planning (ERP) systems, supply chain management (SCM) systems and automation systems, to share data and improve end-to-end visibility. Help companies comply with regulations, standards, and industry standards, which is critical in highly regulated industries such as pharmaceuticals and food. MES implementation process The implementation of an MES system involves a strategic and structured process, which implies dividing its integration by key stages. 1. Functional analysis The first thing is to know and understand the customer's needs, in addition to knowing the current state of the factory (As-Is). In order to locate the level of digital maturity of the factory, both at the administrative level (ERP system) and the control layer (PLC / SCADA, IoT, ...) It will be a starting point to identify objectives and define expected results for the MES system. 2. Define processes and flows to capture data Know the current manufacturing processes and identify areas for improvement to implement and design new workflows that the MES system will optimize by incorporating production data. 3. Configuration Configure the selected software adjusting the processes to the needs of the company. 4. Implementation and validation Perform exhaustive tests to check that everything works correctly and meets the defined objectives, verifying that it is collecting the required information and executing the next steps. This step is very important, as it will start to be part of the actual production process. 5. Evaluation of results & Reporting Through a report, from which we will collect the key performance indicators (KPIs), we will periodically validate if the implementation of the MES system is bringing the benefits it should, for example, calculating the overall production efficiency (OEE), and adjusting if necessary, the strategy. The success of an MES implementation is the result of good work between the software supplier and the group of experts and users of the system. The continuous collaboration during the working period is fundamental to guarantee the good performance and to achieve the established objectives. Advantages of MES in Smart Industry 1 Increased visibility and control A fundamental aspect of MES systems, and why it has become such an essential tool, is its ability to provide real-time visibility into all manufacturing operations. This allows managers and operations managers to monitor the status of production, quality, and machine performance in real time. Real-time information facilitates informed decision making and early identification of problems for subsequent action. 2. Process optimization Process optimization is key to improving operational efficiency. MES systems help minimize machine downtime, reduce bottlenecks and improve resource utilization. This translates into increased production with the same resources or even reduced operating costs, which clearly results in the operational and economic justification for their implementation. 3. Quality improvement Product quality is essential for customer satisfaction and brand reputation. MES systems enable continuous monitoring of production processes, which helps to detect and correct quality problems early. This reduces the amount of defective products and lowers costs associated with rework, scrap and returns. 4. Regulatory compliance In a regulated environment, such as the pharmaceutical or food and beverage industry, MES systems facilitate compliance with strict regulations by providing a detailed record of all production activities. This simplifies audits and avoids potential penalties for non-compliance. In which sectors can an MES platform be applied? Let's remember that an MES system helps to monitor, measure, and improve efficiency in any industrial sector. Although there are sectors where it is more common to implement an MES system, this is a software capable of adapting to the demands of anyone who needs it. Most common sectors: automotive, food industry, energy, pharmaceutical, textile, metallurgy, and manufacturing. What challenges or needs does MES solve? Its role in Industry 4.0 The implementation of an MES system has become an essential and indispensable strategy for companies seeking to remain competitive and efficient in today's industrial environment. It is undoubtedly a central pillar on the road to a digital transformation of industry. It provides real-time visibility, process optimization, quality improvement and facilitates regulatory compliance. Its constant evolution and adaptability ensure that MES systems will remain an indispensable tool for industry in the future. MES as a key technological tool in Industry 4.0 Within the well-known CIM (Computer Integrated Manufacturing) pyramid, the MES system is located between the ERP and the factory shop floor (PLCs, AGVs, robots, machines, operators, SCADA, etc.). The importance of this technological tool is key in Smart Industry due to its role and position, it is the link in factory management between the business management platforms and the hardware and IoT elements of the shop floor. Therefore, investing in an MES system is not only an investment in efficiency and quality, but also in the company's ability to be more competitive and flexible in a constantly changing environment. Connectivity & IoT IA & Data Automation, Connectivity and Augmented Intelligence at the service of a competitive, disruptive and sustainable reindustrialization May 18, 2023