Gone are the days when factories were managed through manual registers and Excel sheets. Technology has entered all arenas, especially in the manufacturing sector. Factories need a 24×7 tracking system that measures each and every move. As a manufacturer, you will understand that such tracking is beneficial for the long-term planning of products.
Manufacturing execution systems are technological marvels that assist you in such tracking. These systems are designed to connect all parts of a manufacturing unit. Your business will flourish due to such tracking systems. Therefore, you should consider adopting MES to increase the productivity and quality of your products.
Core Functions of MES
An MES plays the following roles in your manufacturing process. You will be able to perform these functions with the help of the system.
Production Planning and Scheduling
All the data is displayed on a dashboard. You can see available employees, managers, and machines on it. Moreover, the data is also effortlessly accessible. You can execute the following functions with the system:
- Scheduling Production: Production planning is easier because you can view the materials, development stages, and details of work progress. You can also assess any quality issues in a batch and reschedule its production.
- Allocating Resources: Worker and manager data is available, so you can check the bandwidth of every person on the line. Hence, allocating workload according to bandwidth will ensure smoother collaboration and increase employee engagement.
- Tracking Progress: The entire product genealogy will be available on the dashboard. Hence, you can also track the progress of each batch’s production and plan your actions accordingly.
Real-time Data Collection
Every MES software solution comes with its own set of sensors. These sensors are attached to machines on the production line to check progress. You will have the data for every second of the production line. You can access it from anywhere on a PC or mobile device. Data processing systems connected to these sensors will also display key performance indicators on the dashboard.
Quality Control
You can customise the sensors to check for quality issues in the products. They will be indispensable tools for implementing quality control measures. You can also effectively track a batch’s defects and take corrective actions to avoid hampering production. Moreover, such measures will help you avoid production delays.
Benefits of Implementing MES
The implementation of manufacturing execution systems leads to many benefits for a business. Manufacturers who have adopted MES solutions say that their overall productivity has improved. The technology bridges the gap between functionality and efficiency. Thus, you will see that your operational capabilities have also improved after adopting MES.
Improved Efficiency
Let’s elaborate on this point a bit more. MES streamlines the entire supply chain by organising data. It also connects to systems like Enterprise Resource Planning and Customer Relationship Management. Direct integration with these systems leads to more efficient planning and resource allocation.
Enhanced Product Quality
MES software solutions display the entire genealogy of the products. You can view exactly when and where each batch of products was manufactured. Such genealogy also enhances process management as the supply chain manager can view any bottlenecks in the process. Hence, you can remove these bottlenecks to create faster supply chains.
Regulated Inventory
Inventory management is another hassle that manufacturers face. A proper inventory has only the necessary raw materials and products. Anything more or less will lead to wastage and loss. Hence, a MES ensures that only the required materials and products are stored in the warehouse.
Improved Regulatory Compliance
Manufacturing execution systems also have documentation and certification sections in the product genealogy dashboards. You can upload the batch specifications with the exact production time and place. These steps are crucial for manufacturing units that submit official product information to the government for approval. This feature also creates a paperless shop floor.
More Adaptability
Other obstacles faced by manufacturing units are market trends. The demand for certain products may go down due to changing customer preferences. MES solutions offer quicker and more adaptable responses to such circumstances. You can easily halt production of upcoming batches and steer your operations to manufacture a different product.
Challenges and Considerations
Manufacturing software execution vendors provide complete assistance in adopting the system. However, a new change can bring quite a few challenges.
Cost of Implementation
Manufacturers are often worried about the cost of implementing an MES. The deployment and maintenance of the system are huge investments. However, the long-term return on investment is pretty high compared to initial expenses. This system will reduce capital wastage with enhanced inventory control. Hence, it leads to profitability with improved cost savings.
Integration with Existing Systems
Although many MES software solutions are easily integrated into ERP systems, there is a catch. The ERP and MES must be compatible with each other for smooth integration. Old ERP systems may not be compatible and, hence, cause delays. However, an experienced manufacturing execution systems vendor will solve this problem through data transfer and system upgrades.
Data Security and Privacy
Another challenge is data security. Manufacturers have sensitive data about patents, processes, and recipes that might fall into the wrong hands. However, advanced encryption tools and security measures significantly reduce the risk of data breaches.
Resistance to Change
A new system might be too complex for the employees and managers. The solution to this problem is adequate training and support from the manufacturing execution systems vendor. The employees will adapt to an MES quickly, as the system is quite easy to navigate.
Manufacturing execution systems offer substantial benefits for manufacturers. While implementation challenges are associated, the long-term benefits outweigh the costs. Manufacturers can successfully adopt MES and drive operational excellence in their processes.
Are you ready to transform manufacturing operations with a robust MES software solution? Contact us today to learn more about our state-of-the-art MES software and how it can help you achieve greater productivity!