Misconceptions about the implementation of an MES system

Do you want to implement an MES system in your factory, but still have doubts? Here we debunk five misconceptions about the implementation of this type of industrial software.

To be more competitive and efficient, industrial companies must incorporate the use of new technologies in their factories. If, in addition, their main objective is to obtain real-time information to gain visibility and transparency in their production processes, the tool they need is an MES system.

Most executives and managers know (or at least sense) that implementing this type of software is the first step in moving towards digital transformation and continuous improvement of their production plants. This, however, does not mean that they are confident enough to take the plunge and contact an MES solution provider such as Mapex.

The fears that often hold back this decision are often based on misconceptions. In this article, we debunk five of the most commonly heard misconceptions about setting up an MES system.

5 misconceptions about the implementation of an MES system

1. “Only large industrial companies need an MES system”

Reducing operational costs, detecting inefficiencies and keeping customers satisfied are not challenges specific to large industrial companies. That is why an MES system is a solution for all types of companies that perform manufacturing operations, regardless of their size and industry.

Although large companies will always have more possibilities and resources to undertake a digitization project, SMEs can also benefit from the implementation of an MES solution in their factories.

Just by implementing a production control software such as MapexPM, many SMEs are able to move from paper to a fully automated data capture system; know the status of manufacturing orders in real time and detect any deviations; boost the overall efficiency of their production plants; and standardize processes.

In addition, by choosing specialized MES solution providers such as Mapex, small and medium-sized companies do not have to tackle the project alone; on the contrary, they can count on the support of experts at every stage, from functional and technical design to the deployment of the software in all their work centers.

2. “Implementing an MES system involves a complex and not very cost-effective process”

First of all, the implementation of an MES system is a gradual process: most industrial companies choose to test the software on a pilot production line to reduce risks as much as possible.

In fact, Mapex customers such as Delta Tecnic rate this strategy very positively. “We implemented the solution on a pilot line, which allowed us to see all the gaps that we missed or did not define perfectly during the design phase. It was a very important stage of the project, during which we also obtained a productivity improvement of 10%,” says Andreu Carol, plant manager of the company.

ICM is one of the companies we have collaborated with that highlights the speed with which they began to see the first results and were able to continue with the deployment of the solution. According to its Information Systems Manager, Victor M. Ropero, “once the pilot was approved, we only had to wait a few days to operate in the rest of the plant in the same way”.

Although it is true that these projects require a considerable investment and the total involvement of the organization to identify needs and areas for improvement, it is a solution that pays for itself in the short term, since it allows the detection of inefficiencies in production processes.

Solera’s success story is a good example of the benefits of investing in an MES system. Thanks to the implementation of Mapex, this company dedicated to the plastic injection molding process has reduced personnel costs by 5% of the company’s turnover in three years.

3. “Change management will be a long and traumatic process for the organization”

One of the advantages of MES systems such as Mapex’s is that they have a user-friendly, intuitive and easy-to-use interface. That is why, with proper preparation, organizations can overcome the initial resistance and fears of workers to the solution.

In most cases, operators and, above all, supervisors end up valuing the tool, as it increases the transparency, reliability and efficiency of all processes and decisions that take place in the factory.

To put an end to this third misconception, we provide the example of two companies that have implemented our MES system:

  • “Before go-live, we defined a team of key users per area and trained them intensively. We also involved area and shift leaders in the development of the project to simplify subsequent management. With good planning, the changeover was easy and fast,” explains Juan Agüera, ICT manager at Walki Plasbel.
  • “We convinced those receiving the information that the data being obtained through Mapex was much better than what they had on paper. Finally, they liked the solution because they saw that it saved them a lot of time and effort in the reporting process,” says Rafael Calatayud, IT Project Manager at SPB Global.

4. “If we already have an ERP, we don’t need an MES system”

An ERP controls business management processes, but it does not provide real-time information on the status and evolution of production processes, maintenance activities, quality plans and controls, etc.

The MES system, on the other hand, is designed to meet these needs. This type of software allows industrial companies to digitize the capture of data in the factory, so that they can consult them at any time and instantaneously.

MES solutions send consumptions and production of raw materials, auxiliary materials and semi-finished and finished products to the ERP in real time, for each production order and according to the Bill of Materials (BOM), as well as direct and indirect operator hours.

Thanks to the ability to integrate the MES with the ERP, companies reduce the theoretical calculations of material consumption and, therefore, stock adjustments within the ERP; they have immediate access to direct and indirect hours for production cost calculations, and have real visibility of the Work in Process (WIP).

From the Industry 4.0 point of view, both the ISA-95 model and MESA International emphasize the integration of ERP and MES, and the advantages of corporate and industrial systems cooperating, coexisting and complementing each other rather than competing.

5. “The MES system is not able to adapt quickly to the specific needs of my company”

Most MES systems are modular and scalable solutions that grow with the company to ensure a global view of all its processes.

Specifically, the Mapex platform consists of seven modules that cover all areas of the factory: Production, Quality, Traceability, Maintenance, IIoT, Sequencer and Control Tower. In this way, our customers extend the MES system according to their needs, without having to implement isolated solutions with new interfaces.

Furthermore, in the case of Mapex, we are talking about an open source and customizable platform, in which internal IT departments can implement customizations on the standard functionality. This is a feature that is highly valued by the vast majority of the companies with which we collaborate and that allows companies to make small changes without the help of the supplier.

If you want to go deeper and solve specific questions about the benefits of implementing our MES system in your factory, please contact the Mapex sales team through this form.

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