Innovation is the engine of business growth across industries, and the efficient planning and utilization of operational resources -the core of your information systems- must evolve to keep up. Epicor recognizes that manufacturers globally face a daily array of new challenges and parameters. These include managing rapidly expanding global enterprises and overcoming internal inefficiencies and siloed information. Such obstacles can impede executives’ ability to innovate and compete effectively on cost, quality, and schedule.
The Central Nervous System of Production: Manufacturing Execution Systems (MES)
Manufacturing Execution Systems (MES) act as the production floor’s central nervous system. These critical tools provide a holistic view of the entire production process. Stakeholders gain real-time insights like completion rates, machine and worker efficiency, and material usage. By leveraging MES and adopting best practices, manufacturers can optimize their operations and achieve profitability.
MES: Powering Efficient Production
A MES is a comprehensive software solution that dynamically monitors and controls the entire production process, from raw materials to finished goods delivered to the customer. It offers a range of functionalities to optimize your operations:
- Resource Optimization: MES allocates available resources (machines, personnel, materials) efficiently, ensuring smooth handling of even rush orders.
- Enhanced Production Supervision: Real-time alerts and warnings minimize unplanned downtime, keeping your production running smoothly.
- Paperless Data Collection: Eliminate manual data entry by automatically capturing production data.
- Staff Performance Evaluation: Gain insights into daily staff activity to identify areas for improvement.
- Advanced Material Management: Track materials seamlessly, eliminating duplication and providing real-time updates on inventory and scheduling priorities.
- Product Traceability: Track every manufactured product from production to customer delivery through lot and serial number tracking.
- Real-Time Production Insights: Access consolidated data and key performance indicators (KPIs) like production time, waste levels, and equipment performance – all visualized in dynamic charts for easy analysis.
- Instant Document Access: Quickly access critical documents like construction plans, product specifications, and shipping notes directly within the system.
- Simplified Quality Assurance: MES streamlines quality control practices within your production processes.
- Predictive Maintenance: Create data-driven maintenance plans for your machinery and entire factory for optimal uptime.
MES as Digital Twins
Imagine a virtual replica of your production process, constantly learning and evolving with real-time data. This is the power of a digital twin. It simulates your entire product lifecycle, using machine learning to analyze data and support better decision-making.
Digital twins are ideal for industries that:
- Design, create, test, and optimize products.
- Evaluate “what-if” scenarios to explore different production approaches.
- Implement predictive maintenance to extend equipment life (without needing physical prototypes).
Epicor Advanced MES takes this concept a step further. It seamlessly integrates with your existing systems:
- Automatic Data Collection: MES automatically gathers production data from shop floor sensors, eliminating manual entry.
- Operator Input: Factory workers can add context to the data using touch technology, providing a deeper understanding of production actions.
- Real-Time Communication: The system triggers alerts and notifications to keep everyone informed of critical production issues, allowing for immediate action.
- Simplified Management: MES offers user-friendly dashboards and reports with one-click drill-down capabilities for easy analysis.
- Bi-directional Data Flow: The optional data exchange system ensures seamless integration with your ERP system, allowing information to flow freely across the organization.
The Power of Integration: ERP and MES Working Together
For a truly comprehensive view of your business, synchronizing an ERP and MES is essential. Here’s how they work together:
- ERP: Your Business Roadmap – Your ERP system provides a high-level view, outlining your overall production goals and resource allocation.
- MES: Executing the Plan – MES translates those goals into action on the shop floor, optimizing resource usage and monitoring progress in real-time.
Think of it this way: ERP identifies areas for improvement, while MES equips you with the tools and insights to achieve them.
The benefits of this integrated approach are clear. Studies by IDC show that companies using Epicor Kinetic, a comprehensive ERP with MES functionality (available in Greece, Cyprus, and the Balkans from Athens Technology Center), have achieved:
- Increased Production Capacity by 34%
- Enhanced Equipment Utilization by 12%
By streamlining communication and optimizing production processes, a combined ERP and MES solution empowers manufacturers to achieve significant gains in efficiency and profitability.
Learn more about Epicor Kinetic here
This article is a rewrite of a piece originally published in Metal Industry. You can read the original Greek version here: https://metal-industry.gr/viomichaniki-kainotomia-kai-systimata-mes/
