In our previous article, What is an MES system?, the concept of an MES system (Manufacturing Execution System) and its correlation with the MOM layer (Manufacturing Operations Management) were explained.
Understanding the MES system concept, we now describe the MES system implementation process using Geprom’s methodology.
Define las necesidades para la implementación de un Sistema MDefine the Needs for MES System Implementation
First, a functional analysis is carried out through a consulting exercise in which a multidisciplinary team of experts checks the current state of the factory (As-Is). The factory’s digital maturity is assessed both at the administrative level (ERP system) and at the control layer (PLCs/SCADA, IoT, etc.). As a result, communication flows between systems, plant architecture, and existing data sources are identified. Operational and technological needs that the factory must meet are also detected. Participation of all project stakeholders (systems, operations, engineering, maintenance, and logistics) is required to ensure the success of this phase.
Dimensioning the Functionalities
One advantage of MES systems is that they are modular. This means that depending on each client’s way of working and specific needs, the solution is configured accordingly. The prior functional analysis determines the main functionalities to be addressed with the MES system integration. Common functionalities include:
- Data capture, connection with ERP systems, and real-time monitoring
- Production planning and sequencing
- OEE, KPIs
- Strategic management of breakdowns – MTTR, MTBF
- Traceability
- Consumption management
- Mass balance
- Energy management
- Digital shift management
- Automatic reporting
After this step, the required licenses for MES system implementation are determined. The project can also be carried out in phases, taking advantage of the system’s modularity. This allows the solution to scale according to client priorities.
MES System Adaptability
Once needs and functionalities are defined, it must be verified that the factory is ready for MES integration. Points to review and adapt include:
- Industrial network status
- IoT sensorization level
- Control architecture
- PLC, scales, AGVs, robots programming
- Department and shift organization
- Configuration of external systems that will communicate with the MES
How is an MES System Implemented at Geprom?
Once the previous steps are completed, the MES system is implemented using Geprom’s methodology.
Step-by-Step Implementation Methodology
At Geprom, we apply a structured methodology adapted to each client’s needs, based on a progressive, modular, and scalable implementation. The goal is to ensure efficient MES integration into the production environment with minimal impact on daily operations.
The implementation follows a step-by-step approach including: preliminary analysis, functional design, development and integration, testing, training, commissioning, and post-implementation support.
Analysis and Preliminary Consulting Phase
Every project starts with a consulting phase in which critical production processes, client objectives, and existing systems are identified. This analysis allows designing a customized MES solution aligned with existing workflows and key performance indicators (KPIs) the client needs to monitor.
Technical requirements are defined, modules to be implemented are selected, and the work plan is established.
Integration with Existing Systems (ERP, SCADA, PLC, etc.)
A key factor for successful MES implementation is its ability to integrate with systems already operating in the plant and technical office. At Geprom, we ensure smooth integration with:
- ERP – to synchronize manufacturing orders, materials, stock, and commercial traceability
- SCADA – to obtain real-time data on line status, alarms, and processes
- PLC and machine sensors – to capture production signals, cycle times, stops, and critical variables
Thanks to this interoperability, the MES acts as a central control platform, connecting all levels of the factory and providing complete operational visibility.
MES System Implementation at Geprom
Once MES licenses are installed, the following steps are carried out:
- Data access and capture
- System visualization, configuration, and parametrization
- Commissioning and system validation
- Reporting
- Continuous improvement and support
- Scalability plan (advanced analytics, digital twin, specific modules, etc.)
Data Capture in the Plant
In this first step, Geprom collects and captures data from production processes to incorporate it into the software. This ensures reliable information and allows efficient system configuration. Process and control data capture can be performed in various ways depending on the client’s architecture:
- Access to sensor or direct counter data
- Access to PLC data
- Access to SCADA and historian data
- Access to database data
Either directly through a specific connector or via OPC servers.
System Visualization, Configuration, and Parametrization
Once production data is collected, the MES software is configured. Examples of parameters to configure include:
- Plant hierarchy – defining elements by areas, zones, departments, lines
- Process flow and relevant data
- Relation of consumption and resources
- Operator guides and interfaces
- Etc.
Commissioning and System Validation
At this stage, the planned systems are executed and started. System validation is added based on the verification of previously collected and executed information. Until now, all configuration has been done in a development environment not linked to real production. After commissioning, the system becomes part of the production flow.
Reporting
Once the MES system is implemented and operational, results are visualized and graphs analyzed. By analyzing key performance indicators (KPIs), it is possible to verify whether the MES implementation provides the expected benefits, such as calculating overall equipment effectiveness (OEE).
Continuous Improvement and Support
Finally, depending on the client’s needs, a decision is made whether to implement a Service Level Agreement (SLA) or a Service Management Agreement (SMA).
MES system implementation allows the digitalization of production-related operations, eliminating paper usage, information loss, or human errors. Once data usage is embedded in the client’s culture, a Digital Twin can be created to assess efficiency and the effectiveness of future investments.