Many industrial companies are still unaware of the benefits of implementing a MES (Manufacturing Execution System) in their factory in terms of production control. Most think that with an ERP they already have all their needs covered. However, these types of platforms are not specialized in production management nor do they work with real-time data.
This lack of visibility leads to production losses, undetected downtime, traceability errors, and difficulties in improving operational efficiency. In this context, MES systems have become a key tool for digitizing industrial production, capturing real-time data, and optimizing plant performance.
In this article, we explain:
- What production problems an MES system solves,
- how it helps improve efficiency and plant control,
- what benefits industrial digitalization brings with real-world examples,
- and how Mapex helps you evolve toward a more connected and efficient factory.
Main production problems solved by an MES system
The lack of real-time visibility, manual records, and scattered data remain some of the main obstacles to improving plant efficiency and optimizing decision-making in production.
Digitalization through MES technology enables real-time monitoring of production processes, rapid detection of incidents, and access to reliable information to drive continuous improvement and operational control.
Lack of real-time visibility in production
One of the most common problems in industrial environments is the lack of up-to-date information about what is happening on the shop floor.
Without real-time data, it is difficult to know the status of manufacturing orders, quickly identify incidents, or react to production deviations.
An MES system centralizes factory information and enables real-time monitoring of machines, production lines, operators, and manufacturing processes, improving operational control and decision-making.
Manual data and data capture errors
Some factories still use paper, Excel sheets, or manual records to collect production information.
These types of processes increase the risk of human error, data duplication, and loss of relevant information for industrial management.
With an MES system, data capture is performed automatically from machines, equipment, and shop floor terminals, improving data reliability and reducing administrative tasks.
Undetected downtime and micro-stops
Unplanned downtime and micro-stops often generate significant productivity losses in manufacturing plants.
In many cases, these incidents go unnoticed or are detected too late, making it difficult to analyze root causes and implement corrective actions.
An MES system enables real-time detection of stoppages, automatic incident logging, and analysis of failure patterns to reduce unproductive time and improve equipment availability.
Poor industrial traceability
A lack of traceability makes it difficult to know what has happened during the production process, which materials have been used, or which operators have worked on each manufacturing order.
This can lead to quality issues, regulatory non-compliance, and difficulties in analyzing incidents.
MES systems enable the recording and centralization of all production information, providing full traceability of materials, processes, batches, and operations on the shop floor.
Difficulty in improving OEE
Many industrial companies aim to improve their OEE, but lack sufficient information to identify the main sources of production losses.
Without reliable data on availability, performance, and quality, it becomes difficult to implement effective continuous improvement strategies.
An MES system helps calculate industrial KPIs in real time and enables the detection of inefficiencies that affect overall equipment effectiveness.
Lack of coordination between production and ERP
In some organizations, production information and business planning operate in a disconnected way.
This leads to delays, duplicated tasks, and a lack of synchronization between the shop floor and corporate systems.
An MES system acts as a bridge between production and ERP, enabling real-time information exchange and improving coordination between departments.
Excess paper and manual processes
The use of physical documents on the shop floor slows down processes, hinders traceability, and increases the risk of operational errors.
In addition, the manual management of work orders, inspections, and records consumes time and limits the ability to analyze data afterward.
Digitalization through an MES system helps eliminate paper, automate processes, and improve access to information from any point in the factory.
Lack of data for continuous improvement
Continuous improvement requires reliable information and the ability to analyze what is really happening in production.
When data is incomplete, arrives too late, or is scattered across different systems, it becomes difficult to identify optimization opportunities.
An MES system provides up-to-date KPIs and centralized data that enable continuous improvement and Lean Manufacturing initiatives based on objective, real-time information.
Benefits of implementing an MES system in the factory
These are some real examples of improvements achieved by industrial companies after implementing the Mapex MES system.
Automatic real-time data capture
Manual data collection often leads to errors, delays, and a lack of visibility into what is actually happening in production.
Thanks to the integration of more than 3,000 signals connected to the Mapex MES through IoT, a company in the food sector has been able to automate data capture and process variables in real time.
Digitalizing operations allows them to:
- Monitor auxiliary systems.
- Automatically manage alerts.
- Improve traceability.
- Access reliable information to optimize quality and operational efficiency.
This type of integration helps factories reduce dependence on manual records and improve their ability to respond to incidents on the shop floor.
Greater production control and monitoring
Having accurate information about production operations is key to improving planning and optimizing the use of industrial resources.
A company in the processed meat sector has improved production hour tracking efficiency by 85% thanks to the digitalization of shop floor control with Mapex MES.
The automation of time recording and integration with time attendance systems enables them to:
- Know the real progress of manufacturing orders.
- Access reliable and centralized data.
- Improve planning.
- Increase operational efficiency through data-driven decision-making.
Improvement of industrial productivity
In highly competitive industrial environments, having real-time data makes it possible to identify improvement opportunities that previously went unnoticed.
Delta Tecnic, a company specialized in the plastics industry, has achieved a 10% increase in productivity after implementing the Mapex MES system.
The digitalization of processes and the elimination of manual tasks have allowed them to dedicate more time to analyzing and continuously improving production operations.
As the company explains: “With Mapex we can spend our time thinking about how to improve, not processing data.”
Reduction of unproductive time
Downtime, waiting times, and non-standardized processes generate significant efficiency losses in manufacturing plants.
One of the largest manufacturers of low-voltage electrical equipment has reduced mold changeover time by 30% thanks to the implementation of Mapex MES.
Real-time monitoring of operations and process standardization have enabled them to:
- Reduce unproductive time.
- Improve operational efficiency.
- Optimize the execution of shop floor operations.
Improvement of industrial KPIs
One of the main benefits of an MES system is the ability to improve key production indicators through reliable data and real-time traceability, as explained in this guide on KPIs in the industry.
In the meat processing sector, one of our clients has achieved:
- A 15% improvement in OEE.
- A 4% reduction in product waste.
- Savings of €370,000 in a single year.
These results have been made possible thanks to:
- Automatic data capture.
- Centralization of information.
- Integration between production, quality, and traceability within a single MES platform.
Reduction of scrap and quality improvement
In industrial sectors such as automotive, reducing scrap is essential to improve competitiveness and minimize operational costs.
An automotive company has reduced its scrap rate by 26% in one year thanks to the implementation of the Mapex MES system.
Process monitoring and early detection of deviations have enabled them to apply corrective actions more quickly and improve quality control on the shop floor.
Improvement in decision-making
The availability of real-time information enables faster, more accurate, and data-driven decision-making.
La Pila Food has achieved a 70% faster access to traceability information after fully digitizing its production processes with Mapex.
The elimination of paper and the centralization of information allow them to:
- Quickly access critical data.
- Act in a predictive manner.
- Anticipate potential quality issues.
Elimination of paper on the shop floor
Industrial digitalization enables companies to reduce administrative tasks, improve traceability, and eliminate the issues associated with manual document management.
A leading company in the aerospace sector has digitized more than 600 daily maintenance records thanks to the implementation of the Mapex MES system.
Digital operation management has allowed them to:
- Eliminate the use of paper.
- Improve data utilization.
- Increase operational agility.
- Move toward a more connected and efficient production environment.
Reducing environmental impact through paperless manufacturing
Eliminating paper not only improves operational efficiency but also helps reduce the environmental impact of industrial operations.
One of our clients in the meat processing sector has reduced CO₂ emissions by 475 kg in just two years thanks to the digitalization of its production processes with Mapex MES.
Automating information flows and implementing a paperless strategy has enabled them to optimize production management and move toward a more sustainable industrial model.
MES system vs manual production management
These are some of the main differences between an MES system and manual production management.
| MES System | Manual Production Management |
|---|---|
| Automatic real-time data capture | Manual data recording |
| Up-to-date information and live monitoring | Historical or outdated data |
| Digital and paperless processes | Reliance on paper and Excel sheets |
| Centralized information in a single platform | Data scattered across multiple systems |
| Immediate detection of incidents and deviations | Delayed response to production issues |
| Data-driven decision making | Decisions based on partial information |
| Full traceability of processes and operations | Difficulty accessing production history |
| Integration with ERP, machines, and industrial systems | Disconnected processes and low interoperability |
How Mapex helps digitalize industrial production
Mapex is an MES system designed to help industrial companies improve production control, increase operational efficiency, and advance their industrial digitalization processes.
Our platform enables the connection of machines, processes, and people to capture real-time data and transform shop floor information into faster and more efficient operational decisions.
With Mapex, factories can:
- Capture production data in real time.
- Monitor production lines and processes.
- Manage manufacturing orders digitally.
- Improve industrial traceability.
- Visualize production KPIs and dashboards.
- Integrate production and ERP in a single platform.
- Eliminate paper and manual processes.
- Drive continuous improvement and Industry 4.0 strategies.
Thanks to this global visibility of operations, companies can reduce losses, optimize resources, and improve decision-making on the shop floor.
If you want more information, download our free guide with everything you need to know about MES solutions.
