In diesem Artikel geht es um:
- Was ist ein MES System (Manufacturing Execution System)?
- Wie funktioniert ein MES?
- Die wichtigsten Funktionen eines MES
- Was sind die Vorteile eines MES?
- In welchen Branchen ist ein MES besonders sinnvoll?
- Wie wird eine MES-Lösung eingeführt?
- Welches MES System?
- Erfahrungen unserer Kunden mit einem MES
- Zusammenfassung & Fazit
What is an MES (Manufacturing Execution System)?
An MES is a software-based solution for controlling, monitoring, and optimizing production processes in real time. It acts as a link between the ERP system (Enterprise Resource Planning) at the management level and the machines and equipment on the shop floor.
The goal of an MES is to create transparency, increase efficiency, and drive continuous process improvement.
Typical functional areas of an MES include:
- Machine Data Acquisition (MDA): Production data is made usable and forms the basis for implementing optimizations.
- Production Data Acquisition (PDA): Companies gain precise digital and transparent insights into working times, order progress, and more.
- Production Planning: Live feedback from the shop floor provides an overview of progress and remaining production times.
- Quality Assurance: Inspection processes are directly integrated into the production flow.
- Traceability: Every batch and every work step can be fully documented.
- Maintenance: Companies monitor their maintenance activities and increase equipment availability.
How Does an MES Work?
An MES collects data directly from production, processes it in real time, and presents this information in a transparent way. It communicates both with machines and sensors as well as with the ERP system.
The ERP system serves as the control level of a manufacturing company. It stores and manages key business data. A company may produce based on stock and inventory levels or in response to customer-specific orders. In both cases, the ERP system generates a production order and releases it for manufacturing.
The MES receives master data (resources) and transaction data (production orders), which it processes into a work queue. This is then sent to the machines on the shop floor. Employees receive the planned orders at the terminals and start the equipment. For the purpose of production optimization, the system automatically performs machine and production data acquisition (MDA/PDA). The collected data is fed back to the ERP system and made available for controlling.
Additional MES functions may include production planning, quality assurance, traceability, and maintenance.
A typical workflow looks like this:
A production order is created in the ERP system.
The MES imports the order and schedules it in detail.
Machines continuously supply actual data, such as quantities or downtime.
The MES analyzes this data and identifies deviations.
Results and KPIs are reported back to the ERP system.
The Key Functions of an MES
An MES – Manufacturing Execution System – connects management with the shop floor and provides a wide range of functions, some of which were already outlined in the section „What is an MES?“ The MES ensures that people, machines, and materials work together seamlessly.
With the help of a reporting function, companies can create dashboards and reports to analyze performance indicators in real time. In addition, modern MES solutions include features such as:
Order Management: The MES knows which job comes next. Work instructions are distributed digitally instead of on paper. The production software ensures that every machine and every employee knows exactly what to do.
Real-Time Data Collection: The MES monitors what happens on the shop floor. It gathers machine data, quantities, and scrap – without paperwork.
Quality Management: Errors are detected immediately. The Manufacturing Execution System records inspection values, compares them with target values, and stops production if necessary – reducing scrap and rework.
Traceability: Who produced what, when, and how? The MES knows the answer. Batches, serial numbers, material usage – everything is documented without gaps.
Resource Planning: The MES software plans machine utilization, material flow, and personnel deployment. The goal: short lead times, full capacity, and on-time delivery.
KPIs and Analytics: The MES system provides clear metrics such as Overall Equipment Effectiveness (OEE), downtime, and scrap rates – key figures that serve as the basis for sustainable production optimization.
An MES turns data into decisions – quickly and accurately. It saves time, reduces costs, and improves quality. Those who use it have full control over the pulse of production.
What Are the Benefits of an MES?
An MES is the digital core of modern manufacturing. It connects management with the shop floor and ensures that information reaches exactly where it’s needed – instantly and without detours. The result: greater transparency, higher quality, and noticeably improved efficiency.
With an MES, companies gain transparency and real-time data. In addition, it offers the following advantages:
Full Transparency in Real Time: With an MES, you have complete visibility over your entire production process – from the first material movement to the finished product. Machine states, order progress, quantities, and scrap are all automatically recorded and displayed in real time. You always know what’s happening in your production and can react quickly when something deviates from plan.
Higher Product Quality: Quality begins with control. The MES continuously records inspection data, compares it with target values, and immediately reports deviations. Sources of error are detected early and eliminated before scrap occurs. This saves costs, safeguards your quality standards, and strengthens customer trust.
Increased Efficiency Through Optimized Processes: A Manufacturing Execution System ensures smooth operations. Orders are automatically assigned to the right machines and operators, material flows are optimally planned, and downtime is reduced. Lead times shorten, productivity increases – allowing you to handle more orders in the same amount of time.
Complete Traceability: Who produced what, when, and with which material? With an MES, you can answer that question at any time. Every batch, serial number, and production step is documented. This is crucial not only for quality management and certifications but also for compliance with legal requirements.
Data-Driven Decisions Instead of Gut Feeling: The MES provides reliable key figures – from Overall Equipment Effectiveness (OEE) to downtime and scrap rates. This data is available clearly and up to date, enabling you to make fact-based decisions and continuously improve your production performance.
More Flexibility and Responsiveness: Sudden order changes, unexpected machine stoppages, or material bottlenecks? With an MES, you stay in control. You can adjust plans, shift priorities, and reallocate resources – without losing oversight.
Compliance and Regulatory Support: An MES helps you meet all relevant standards, certifications, and legal requirements – from ISO 9001 quality management to industry-specific guidelines (e.g., BRC, IFS). Inspection and production data are automatically documented, and reports can be accessed at any time. This reduces audit effort, minimizes legal risks, and ensures that your production always operates in compliance.
Scalability: An MES grows with your needs. Whether you’re introducing new production lines, connecting additional sites, or manufacturing new product variants – the system can be flexibly expanded and adapted. This provides a future-proof platform that manages and optimizes your processes efficiently, even as production volumes increase.
In Which Industries Is an MES Especially Valuable?
Manufacturing Execution System (MES) delivers greater transparency, higher efficiency, and reliable quality assurance – across all industries. Even in complex production environments, a production system provides decisive advantages.
Pharmaceuticals and Medical Technology
In pharmaceutical and medical device companies, compliance with GMP, FDA, or ISO standards is mandatory. A production system supports batch tracking, ensuring both product quality and regulatory compliance – while simultaneously increasing efficiency.
Food and Beverage Industry
In food production, an MES helps maintain strict hygiene standards, monitor expiration dates, and react quickly in the event of a product recall. This minimizes risk and strengthens customer trust.
Automotive and Supplier Industry
In automotive manufacturing, precision and timing are everything. An MES controls production processes in real time, guarantees complete traceability, and helps meet specifications accurately. The result: less downtime, higher quality, and on-time delivery.
Plastics Industry
The plastics industry is characterized by rising energy costs, high product variety, and strict documentation requirements. An MES enables paperless, fully traceable processes, reduces scrap, and shortens setup and lead times.
Metal Industry
In metal production, companies can use an MES to implement intelligent energy monitoring, automate data collection, and optimize sequencing — reducing material consumption and improving costing accuracy.
An MES Pays Off in Every Type of Production
No matter what kind of production you run, an MES increases efficiency, ensures quality, and creates transparency. For any manufacturer, implementing an MES is always the right move — laying the foundation for long-term competitive advantage.
How Is an MES Solution Implemented?
Implementing a Manufacturing Execution System (MES) is a strategic step that will sustainably transform your production. The goal is to digitally connect processes, create transparency, and increase efficiency – from the shop floor to management.
A key prerequisite for successful implementation is selecting the right MES provider – learn more here.
Once you have chosen an MES provider, you will go through several phases together:
Analysis and Goal Definition
The process begins with an assessment: Which processes are already digitalized? Where are the main bottlenecks? Which KPIs do you want to monitor in real time? Together with your MES provider, you define which functions the production software needs to cover – from Machine Data Acquisition (MDA) and Production Data Acquisition (PDA) to Quality Management and Traceability.
Integration and Training
The MES is seamlessly integrated into your existing system landscape. Machines are connected, data flows defined, and user rights configured. At the same time, your employees receive practical, role-based training to ensure the system runs smoothly from day one.
Step-by-Step Implementation
MES implementation is carried out in stages: starting with a pilot area on one machine, followed by rollout across additional production lines. This allows insights from practical use to be applied immediately and any adjustments to be made early on.
Continuous Optimization
Implementation is not the end of the process – it’s the beginning. The MES provides data from which targeted improvement measures can be derived. This enables your processes to evolve continuously.
Implementing an MES is not just an IT project. Those who plan carefully, execute step by step, and actively involve employees lay the foundation for transparent, efficient, and future-proof manufacturing.
Which MES System Is Right for You?
A key prerequisite for successful implementation is selecting the right MES provider. There are many companies on the market, each with its own unique strengths. Before making a decision, define what matters most to you when choosing an MES partner – for example, modularity of the production software, flexibility, costs, personal support, and expertise in interfaces and machine connectivity.
To get an initial idea of which company might be the best fit, start by researching their websites. Most MES providers also offer free consultation sessions where they present their solutions and discuss your specific requirements. Take advantage of these opportunities to narrow down your shortlist of potential MES partners.
In the end, beyond the provider’s qualifications, your decision will likely also depend on investment level and personal rapport.
Tip: Make sure to review Success Stories that the MES provider has already implemented for other customers. These give you valuable insights into how the company works in practice.
With MES FASTEC 4 PRO you can monitor and control your production equipment, machines, and workflows in real time. The system collects data directly from your production lines, enables precise planning and analysis of production processes, and supports data-driven decision-making across your organization.
Simple MES Implementation
To make potential analysis and production optimization possible even with minimal effort, FASTEC offers smartOEE for its customers. This 3-month project uncovers machine potential, initiates optimization measures, and sustainably increases productivity. FASTEC provides a plug & play system consisting of powerful software and reliable hardware.
The flexible monthly rental option allows for a fast and cost-effective entry into the digital factory. Production data is collected and can be evaluated either on-premises or in the cloud. With the automatic calculation of OEE, companies can derive targeted optimization measures and increase the productivity of their operations.
Customer Experiences with an MES
Many companies have already optimized their production, increased transparency, and improved efficiency through the use of an MES.
Here you can find success stories from a wide range of FASTEC customers:
In Summary:
A Manufacturing Execution System (MES) is production software designed for the manufacturing industry. It handles tasks related to data collection and analysis. With an MES, machine and production data can be digitally recorded and evaluated to optimize manufacturing performance.
This includes information such as cycle times, machine states, reasons for downtime, and duration. The system automatically calculates the OEE. Analyzing this data provides valuable insights into potential sources of error in the production process, enabling companies to detect disruptions in real time and to make targeted, long-term improvements.
The advantages of an MES include cross-departmental transparency, increased production efficiency, complete traceability, and real-time data for well-founded decision-making.
At the same time, an MES is much more than just production software. It is a strategic tool for the digitalization and optimization of manufacturing processes. Companies that successfully implement an MES benefit from greater transparency, improved quality, and enhanced efficiency – making it an essential component of modern Industry 4.0.
Once you’ve chosen the right MES provider and defined your goals, nothing stands in the way of a successful implementation. Some companies even offer dedicated entry-level solutions to keep your initial investment manageable – such as FASTEC’s smartOEE.
