Solving Manufacturing Challenges with MES

Manufacturing execution systems (MES) often get touted as the one-stop solution for all manufacturing woes—from streamlining processes and boosting productivity to integrating data seamlessly across the enterprise. But let's face it, for many manufacturers—especially the smaller ones—jumping headfirst into a full-blown MES platform can feel like using a sledgehammer to crack a nut.

Sometimes, addressing specific use cases one by one is the smarter, more pragmatic approach. This way, you can solve real problems without getting bogged down in unnecessary complexity. Following is a look at five core uses cases for MES.

Overall equipment effectiveness (OEE). OEE is like the holy grail of manufacturing KPIs. It measures how efficiently your equipment is running by looking at availability, performance and quality. Implementing an OEE tracking system helps you pinpoint bottlenecks, reduce downtime and generally get things humming along more smoothly. What’s great is that OEE solutions are often part of MES platforms and can be installed a la carte without the need to invest in an overarching MES platform. By focusing on OEE first, you can start with a clear goal and see measurable outcomes without overhauling your entire system.

Downtime tracking. The real magic of downtime tracking lies in the automated collection of data. Rather than relying on manual categorization, which can be prone to errors and inconsistencies, a comprehensive OEE solution should automatically record fault codes and downtime reasons such as changeover and scheduled maintenance. Integrating directly with live status from PLCs ensures accurate, real-time data collection, making it much easier to identify and address issues promptly.

Batch recipe management. In industries like pharmaceuticals and food and beverage, precise formulations are crucial. Batch recipe management ensures that the right ingredients are used in the correct proportions and sequences. An automated system reduces the risk of human error, ensuring consistency and quality while helping maintain compliance with industry standards. Recipe management systems can range from simple setups using MS Excel to advanced custom-scripted web applications interfacing with other internal systems.

LIMS data integration. Laboratory information management systems (LIMS) handle data from laboratory operations. Integrating LIMS with your manufacturing processes can enhance data accuracy and traceability. This seamless data flow between the lab and the production floor means quality control data is always at your fingertips, ready for those critical production decisions. Modern historian systems can link LIMS data through external data sources or even leverage the historian itself for logging data from analytical instruments connected via OPC, for instance.

Bi-directional workflow implementation. Integrating your enterprise resources planning (ERP) systems with industrial control systems (ICS) ensures data flows smoothly in both directions. This bi-directional workflow improves coordination and decision-making, providing real-time visibility into production metrics and business KPIs. This is typically where full-blown MES platforms excel. However, a simple example of this type of integration can be accomplished using a shared SQL table between the systems, enabling basic data exchange. In more complex applications, it can involve tracking production and consumptions in real-time, where the ERP system sends production orders to the ICS, which then updates the ERP with real-time production data and material consumption. This can be achieved through modern middleware solutions that facilitate real-time data exchange and ensure that both systems are always synchronized.

Adoption considerations

Diving into a full MES platform can be a massive investment—time, money and resources all need to be considered. For small to mid-sized manufacturers, starting with specific use cases often makes more sense. It allows you to address pain points without the need for a complete system overhaul, making it easier to demonstrate ROI on smaller, focused projects. Plus, it’s more flexible, allowing you to implement and scale solutions gradually.

But before you start tackling any MES application, it’s crucial to undergo some front-end engineering to define your data integration needs clearly. Methods like value stream mapping help visualize and analyze the flow of materials and information, ensuring that you identify the most critical areas for improvement and set clear, achievable goals for each project. This approach helps in designing tailored solutions that fit your specific needs, providing a roadmap for phased implementation and ensuring that resources are allocated to the most impactful projects.

Choosing the right partner is also key to successfully implementing use cases such as the ones described above. Look for a partner who understands your specific needs and can provide customized solutions without trying to sell you unnecessary software or services. You want someone with a proven track record who understands both OT (operations technology) and IT environments. Flexibility and customization with off-the-shelf solutions is crucial, as are ongoing support and training to ensure successful adoption and help build internal capabilities for future projects.

Dan Malyszko is vice president at Malisko Engineering, a certified member of the Control System Integrators Association (CSIA). See Malisko Engineering’s profile on the CSIA Industrial Automation Exchange.