Manufacturing Execution System
What is an MES?
In today’s fast-paced manufacturing landscape, companies are constantly looking for ways to increase efficiency, reduce costs and ensure the quality of their products. A key tool in achieving these goals is the Manufacturing Execution System (MES). But what exactly is an MES and why is it so important for modern production operations?
Definition
MES: The link between planning and shop floor
A manufacturing execution system (MES) is software that translates production orders from the ERP system into manufacturing, monitors and controls their execution in real time and documents the results.
A Manufacturing Execution System (MES) is an integrated software solution that bridges the gap between the enterprise level (e.g. ERP systems for business planning) and the production level (the so-called shop floor).
While an ERP system handles the long-term planning of resources and orders, the MES is responsible for translating these plans into the daily operations of manufacturing, as well as monitoring and controlling them.
In other words, an MES system provides real-time data on the entire production process, enabling precise control and optimization of manufacturing operations. The MES acts as the “brain” of the shop floor, ensuring that the right products are produced at the right time using the right resources.
Level Model
Where does the MES sit in the company?
The MES sits at the operations level – between enterprise planning in the ERP system and automation with SCADA, HMI and PLCs. The international standard ISA-95 (IEC 62264) describes this with a level model from the field level (0) to the enterprise level (4); in German-speaking countries, the term automation pyramid is also common. In the Industrial Internet of Things (IIoT), the levels are becoming more permeable, but the division of tasks remains.
Data flows in both directions: Orders, master data and deadlines come down from the ERP system. The MES schedules them in detail, passes them on to machines and workstations and reports quantities, times, quality results and KPIs such as OEE back up.
The time horizons differ too: An ERP system plans in months, weeks and days, an MES in shifts, hours and minutes, while SCADA and PLCs react in seconds and milliseconds.
Functionality
Key functions of an MES
A comprehensive MES system offers a wide range of functions aimed at maximizing production performance. The German guideline VDI 5600 describes the tasks of an MES, including order management, detailed scheduling, data acquisition, performance analysis and quality management. The most important functions include:
Production planning and control
Operational and machine data acquisition
Quality management and documentation
Traceability
Maintenance management
Personnel and resource planning
Performance analysis and KPIs
Energy management
Benefits of an MES for manufacturers
By using an MES with the appropriate functionality, production processes can be monitored, controlled, and optimized in real time. Many MES providers also address industry-specific requirements, such as additional documentation features in the pharmaceutical industry or integration capabilities for heterogeneous machine fleets in mechanical engineering. Companies can benefit from the use of an MES in various ways:
Increased productivity and efficiency
Real-time monitoring of production processes allows for quick identification and resolution of bottlenecks, leading to optimized utilization of machines and personnel.
High and consistent product quality
Continuous quality inspections and complete traceability help detect defects at an early stage and reduce scrap / reject rates.
Reduced operational costs
More efficient processes, reduced waste and optimized resource utilization lead to significant cost savings.
Data-driven decisions
Detailed insights into all production processes enable informed decision-making and improved planning.
Faster responses to changes
The ability to respond flexibly to unforeseen events (e.g. machine failures, material shortages) increases the agility of production.
Differentiation
MES vs. ERP vs. SCADA: What are the differences?
MES systems are often either confused with ERP or SCADA systems, or their functions are not clearly distinguished.
ERP (Enterprise Resource Planning)
The focus of an ERP system is on company-wide planning and management of resources, finances, sales, and procurement. ERP systems are often modular in structure and play a central role in production planning. They typically support higher-level scheduling and capacity planning of orders, as well as coordination with other departments.
SCADA (Supervisory Control and Data Acquisition)
A SCADA system is used for the direct control and monitoring of machines and processes at a very detailed, technical level. It typically consists of multiple components such as sensors, PLCs, HMIs, and a central control unit. SCADA systems operate close to the machine level.
MES (Manufacturing Execution System)
The MES serves as the bridge between ERP and SCADA. It receives production orders from the ERP system and translates them into detailed instructions for the shop floor, which are then transmitted via SCADA systems or directly to the machines. At the same time, it sends real-time data from the shop floor back to the ERP system to update planning.
Comparison
ERP, MES and SCADA at a glance
The table summarizes the task of each system and the level at which it operates.
| Criterion | ERP | MES | SCADA |
|---|---|---|---|
| Task | Plans resources, orders, purchasing, sales and finance across the company | Plans, directs and documents orders and manufacturing processes in production | Monitors and controls machines and plants, acquires data and reports alarms |
| Level according to ISA-95 | Enterprise level (4) | Operations level (3) | Supervisory level (2) |
| Time frame | Months, weeks, days | Shift, order, hour | Seconds to minutes |
| Data | Customer orders, bills of materials, stock, costs | Production orders, quantities, quality and KPIs such as OEE | Process values, alarms and trends |
| Users | Sales, purchasing, controlling, production planning | Production management, work preparation, quality assurance, operators | Control room staff, shift supervisors, maintenance |
| Connections | MES, suppliers, customers | ERP above, SCADA, machines and workstations below | PLCs and field devices via standard protocols such as OPC UA |
What matters is the integration of the three systems: The benefit only arises when orders and feedback flow without media breaks. The boundaries are fluid: Some ERP systems include manufacturing modules, and many SCADA systems take on simple MES tasks. How SCADA differs from a DCS and an MES is shown in the comparison on the SCADA page.
Market Situation
Market diversity: MES solutions for a wide range of requirements
The MES market is diverse, offering solutions tailored to a wide range of industries, company sizes, and specific requirements. In the German-speaking region alone, there are over 150 providers offering MES systems in various forms and with different focuses.
There is no “one-size-fits-all” MES system. The offerings range from standardized software packages that cover a broad set of functions and can often be implemented quickly, to highly customizable systems tailored precisely to the complex processes of a specific company.
Some systems are modular in design, allowing companies to start with only the most urgently needed functions (often operational and machine data acquisition) and later expand the system with additional modules (e.g. quality or maintenance management).
Other solutions are tailored to specific industries, such as the automotive sector, food production, or the pharmaceutical industry, taking into account industry-specific standards and regulations (e.g. GMP guidelines).
The presence of hundreds of providers in the market illustrates the balancing act MES systems perform: Standardizing individual requirements across specialized industries.
A distinction can also be made between cloud-based MES systems, which offer flexible scalability and lower initial investment costs, and on-premise solutions, which provide maximum control over data and infrastructure (see also Cloud vs. On-Premise).
Choosing the right MES system therefore strongly depends on the individual production processes, corporate strategy, and desired level of integration. A structured analysis of a company’s needs is crucial to finding the optimal solution – one that delivers long-term value and drives the digital transformation of production for years to come.
Strategic challenges when implementing an MES
- Make-or-buy decision: Standard software vs. in-house development vs. hybrid approaches (MES: Make or Buy?)
- Integration depth: Integration with ERP, PLM, and shop floor systems
- Implementation strategy: “Big Bang” vs. gradual implementation by module/plant
Implementing an MES in 5 steps
An MES is best introduced step by step. These five steps have proven themselves – regardless of whether a standard MES is bought, a custom system is built or both are combined:
Define goals and KPIs
Which problems should the MES solve – transparency about downtime, less scrap, complete traceability? Measurable goals such as a higher OEE make the benefit verifiable later on.
Map processes and the system landscape
Describe orders, operations and inspections and record the existing systems: ERP, machines and controllers, databases, Excel lists and paper forms. This determines the interfaces needed and the integration effort.
Decide on make, buy or hybrid
Standard software for the core functions, in-house development for company-specific processes or a combination of both. No-code platforms make in-house development possible even without a large IT department.
Start with a pilot area
Instead of a “Big Bang”, start with one line or one use case, such as machine data acquisition with an OEE dashboard. Experience and feedback from operators feed directly into the next step.
Roll out step by step and measure
Add further functions and plants, check the KPIs from step 1 regularly and develop the system further alongside your processes.
manubes as an MES Solution
Building your own MES with manubes
Implementing a comprehensive MES system doesn’t have to be a massive project that disrupts your daily operations.
Our manubes platform offers an innovative solution that enables you to gradually build your own highly flexible MES based on no-code development. manubes users are able to create powerful applications tailored to a specific manufacturing environment without requiring advanced programming skills.
manubes allows companies to flexibly implement the needed functionality – whether it’s the digital collection of production data, automation of quality control, or optimization of maintenance processes.
The step-by-step implementation and the ability to tailor the system precisely to your individual workflows not only result in faster employee adoption, but also ensure optimal use of all efficiency potentials. With manubes, it’s possible to design an MES that fits your production’s unique requirements perfectly and evolves flexibly alongside your processes.
Technically, data reaches the manubes cloud via Edge Nodes and Edge Connectors – from OPC UA servers, SQL databases and REST interfaces. It is structured in the Datamodel Designer, dashboards and input forms are created in the Page Designer, and automated processes in the Workflow Designer. Companies that already use an MES can also use manubes to complement it, for example for company-specific dashboards or workflows.
Build your own MES step by step
Capture machine data, control orders and visualize KPIs – with manubes, without any programming.
Try it nowConclusion
MES as a cornerstone of manufacturing success
An MES system is more than just software – it is a critical building block on the path to the smart factory and Industry 4.0. By creating transparency, optimizing processes, and enabling informed decision-making, a well-implemented MES empowers companies to stay competitive and meet the demands of the modern market.
If you are interested in learning how manubes can address your specific production challenges and what benefits it can offer your business, feel free to contact us for an individual consultation.
Frequently asked questions about MES
What is an MES in simple terms?
An MES is the software that mediates between enterprise planning and machines. It receives orders from the ERP system, schedules them for production, tracks their execution in real time and reports quantities, times and quality results back. This lets production managers and operators (as mobile-enabled connected workers) see at any time what is being produced and where problems arise.
What is the difference between ERP and MES?
An ERP system plans company-wide and long-term: Customer orders, materials, purchasing, costs. An MES puts this planning into practice in production and works in shifts, hours and minutes. It controls production orders, acquires machine and operating data and feeds the actual data back to the ERP system.
What is the difference between MES and SCADA?
A SCADA system monitors and controls machines and plants at a technical level, within seconds to minutes. An MES organizes the production orders above it: It plans, directs and documents what is produced on which machine and when. SCADA supplies the MES with the process and machine data it needs.
What are the functions of an MES?
The core functions of an MES include production planning and control, operational and machine data acquisition, quality management, traceability, maintenance, personnel planning and performance analysis with KPIs such as OEE. The German guideline VDI 5600 describes these tasks in detail.
What is ISA-95?
ISA-95 (internationally IEC 62264) is a standard that structures companies into levels from the field level to enterprise planning. The MES belongs to the operations level (level 3) between ERP (level 4) and automation with SCADA, HMI and PLCs. The standard also defines which information is exchanged between ERP and MES.
How much does an MES cost?
The cost of an MES depends on the scope of functions, the number of machines and sites, the integration effort and the operating model. Cloud-based MES solutions usually require a lower initial investment because no in-house server infrastructure is needed. A step-by-step implementation spreads the costs and shows the benefits early on.
Can you build your own MES?
Yes. With no-code platforms such as manubes, MES functions can be built without programming skills – for example machine data acquisition, order dashboards or quality inspections. Many companies combine a standard solution for the core functions with their own applications; the trade-offs are discussed in MES: Make or Buy?.
Product video: Get to know manubes
Further information
Try manubes for free
Test the different manubes features in your personal cloud environment.
Get started
'/%3E%3C/svg%3E){kind=small}