What is a Manufacturing Execution System (MES)?

Food and beverage manufacturers constantly strive to meet stringent food industry regulations and maintain high quality and efficiency standards. As competitiveness has soared, businesses need to work even harder to find the best way to optimize the production process to stay ahead of their competitors and survive in the market.

Digital solutions, mainly Manufacturing Execution Software (MES), have emerged as critical tools for liaising different supply chain stages, creating real-time visibility and control, and leading to business success.

In this article, we will explore the MES in detail. We’ll dive deeper into the MES definition, its functionality, benefits, main implementation challenges, and more. If you are looking for a solution to enhance your food manufacturing performance, compliance, and product quality, understanding MES will equip you with the knowledge to make informed decisions.

What Is a Manufacturing Execution System (MES)?

MES stands for Manufacturing Execution System, a software-based solution that helps monitor and control production from raw materials to finished goods, including scheduling, quality, maintenance, logistics, and management. MES joins enterprise-level systems like ERP or administration and the production floor, including machines and IoT devices.

The manufacturing execution systems (MES) aim to monitor and document manufacturing processes in real-time. MES can gather real-time data from different sources and devices, such as equipment and sensors, to give the most accurate overview of the current production state.

With MES, food manufacturers can efficiently manage materials, labor, equipment, and processes, make data-driven decisions, find and resolve potential issues, reduce downtime, and improve product quality.

MES is an excellent solution for enhanced quality control, better traceability, and inventory management. It helps optimize and centralize operations, enabling businesses to allocate resources correctly and bringing faster production and profit growth.

MES is a universal tool that can work in cross-functional environments. It enables comprehensive product lifecycle management, especially in regulated industries like food and beverage.

History of MES

It all started long ago. Manufacturers have always strived to improve their production. The MES concept was formed in the 1990s, and it served as a bridge between the shop floor and management levels and helped optimize operations.

Later, in 1992, a group of software development consultants and solution integrators created the Manufacturing Execution Systems Association (MESA), now the Manufacturing Enterprise Solutions Association. The association established a MESA model – eleven mandatory functionalities that MES applications must have.

MES functionalities developed in the 2000s when the focus was on integrating MES with ERP and other standardization advancements. International Society of Automation developed an ANSI/ISA-95 standard that facilitated the integration of MES by implementing terminology and established activities, functions, and interfaces for manufacturing execution systems.

The fourth industrial revolution has fostered the development of Internet of Things (IoT) technologies, Artificial Intelligence (AI), robotics, cloud computing, and more. MES has improved along with these technologies, so now food manufacturers can benefit from even greater possibilities.

MES became cloud-based, and implementing them has become much more manageable, making operations even faster. Also, MES integrates with cyber-physical systems, which means MES can combine both hardware and software for enhanced monitoring.

MES can now work with IoT devices, so manufacturing monitoring has become more comprehensive and detailed. With in-depth analytics and AI technologies, MES can better analyze the data received from thermometers and sensors.

Through the years, MES has become an established, more developed, and critical system for food manufacturers, enabling them to receive detailed information for more data-driven decisions.

ISA-95 Levels

The ISA model consists of 5 levels, presenting the place of MES in the manufacturing system:

Level 0 – Physical production process
Level 1 – Involves physical sensors on the shop floor to collect manufacturing data.
Level 2 – Monitoring and supervising where controllers, like a programmable logic controller (PLC), regulate the equipment.
Level 3 – Manufacturing operations management layer, where you must apply MES.
Level 4 – Business planning through systems like ERP or CRM.

As we can see, MES connects equipment and business administration systems, such as ERP.

How Does MES Work?

MES functionality can be slightly different depending on the company that uses it. However, it has some established capabilities, so let’s see some core features of MES and how it works:

Data Collection and Integration

MES must collect data from machines, sensors, or operators and integrate it with other systems, such as an ERP (enterprise resource planning) system or SCM (Supply Chain Management). This integration allows a synchronized data flow across the systems.

Scheduling

MES enables efficient resource, equipment, materials, labor, and tool allocation. Its functionality helps accurately track work orders, job statuses, timelines, and related information. You can minimize downtime thanks to the system’s ability to adjust schedules depending on demand, production delays, or available resources.

Quality Management

Another MES capability is ensuring and maintaining product quality. MES can automatically conduct and record quality checks to address and prevent potential issues. Real-time monitoring functionality helps control quality parameters to confirm they meet the standard. Overall, MES will ensure systematic and productive quality control.

Resource Allocation

This feature means controlling what people, machines, and materials should do or where they should go, what is being done now, and what tasks are ready. It provides real-time visibility of resources.

Dispatching Production Units

Dispatch information is an order in which work should be done. The sequence modifies as new crucial events happen. In other words, it means routing the resources to produce a product.

Inventory Management

MES software manages inventory level tracking, as the system effectively monitors ingredient levels and tracks product movement and usage. As a result, you will get accurate inventory levels, minimize stockouts or overstock, reduce waste, and boost supply chain efficiency.

Product Tracking and Genealogy

Once you implement MES software, product tracking will be much easier. The system will track and trace the product’s location at any supply chain stage. It will also gather information about the source, equipment involved, lots and batches, etc.

If you’re looking for more information, our complete guide on food traceability is the perfect next step.

Performance Analysis

A manufacturing execution system can help you analyze production performance. It tracks KPIs (Key performance indicators) like efficiency or quality analyses and draws progress reports. Employees can make data-driven decisions to find gaps and areas for improvement, initiate continuous improvement, and develop optimization strategies.

Maintenance Management

MES has maintenance management software features and will help proactively maintain facility equipment. It will track machine performance and maintenance schedules and create alerts and reports. Equipment effectiveness will improve, and there will be fewer risks of downtime.

Process Management

Process management provides complete visibility over the production processes, including new orders, WIP (Work in Progress), and finished goods. The work will be structured and sequential.

Document Management

MES documents everything it monitors. Moreover, it helps food and beverage manufacturers efficiently manage their records, keeping them accessible when needed, for example, during an audit. On a cloud platform, you can digitize your paperwork and store plans, checklists, instructions, drawings, etc..

Labor Management

You can easily manage the aspects related to your workers: timekeeping, certifications and qualifications, schedules, personnel operations, and more.

Manufacturing execution systems (MES) integrate with other systems, creating a seamless collaborative environment between departments for work optimization and data-driven cross-functional decisions.

They make manufacturing processes more visible. The system monitors and controls production activities from raw materials to the end product to find potential issues as they arise. Accordingly, once a problem is identified, immediate corrective actions can be initiated.

Let’s say one of the conveyors has broken down. MES gathers the data and alerts the worker in charge to handle an issue quickly.

By leveraging MES capabilities like real-time monitoring, quality control, process and progress management, labor management, and others, food manufacturers will significantly improve their performance, maintain food safety compliance, and maintain efficient and seamless workflows.

Implementing MES Into the Food and Beverage Business

Engaging a manufacturing execution system is a complex but structured task. Here are steps to successfully implement MES software into your food and beverage business.

Plan and Assess

Before implementing a manufacturing execution system, you must assess the scope, goals, and requirements. You must also understand how ready the company is and identify the gaps in the current system.

Choose What MES Software You Want

You need to decide what software provider you want. Research and compare different solutions. The criteria for the comparison could be affordability, compatibility, functionality, scalability, user-friendliness, features, etc. Check for feedback to see real cases of software usage.

Prepare the Plan

You must develop an implementation strategy, create a project plan, and involve stakeholders, including the IT team, management, quality control team, etc. To successfully implement MES, use a standardized methodology, such as Scrum. The team must be on the same page and understand the process’s structure. This will facilitate the process.

Prepare the Environment

Ensure the software is compatible with existing systems and that your IT infrastructure supports it. You may need to update data security terms or upgrade the hardware. Make sure the software can integrate with existing systems, such as ERP, and that it meets your specific requirements and fits the workflow.

Data Transfer

Data migration includes moving existing data, such as production data, inventory and quality records, reports, etc., to the MES.

Training

Ensure that all employees working with MES are educated on how to use the software. Most software nowadays is user-friendly, so the intuitive interface will help workers quickly learn the ropes.

Implementation

Now, you need to test the system carefully. Once you see no issues, you can deploy the software.

Continuous Improvement

The food industry and technology evolve, so after implementing MES software, you must constantly monitor its performance and upgrade it according to the latest food safety regulations and technological advancements.

Implementing new software can be daunting, but it’s worth a try, as MES software improves quality, streamlines the production process, and brings many other benefits.

How Can Food Companies Benefit From MES?

MES software brings significant advantages to different aspects of food manufacturing, including machine process control, recipe management, traceability, and more. Let’s look at how MES software can benefit your food and beverage business.

Visibility and Efficient Production

MES helps you reach transparency in production, boosting efficiency and productivity. You can handle large volumes of information in one system that analyses it for you. It helps increase performance, quality, and availability.

MES Makes Production Error-Proof

MES ensures automated workflow, monitoring, and analysis, which helps companies reduce waste and allocate resources correctly. It will also help minimize human factors that can lead to costly mistakes.

Enhanced Inventory

A manufacturing execution system makes inventory management highly precise, outperforming any other system. MES can track raw, finished, and semi-finished goods in the supply chain and transfer the information to an enterprise resource planning (ERP) system. As a result, you will improve traceability and supply chain efficiency.

Improved Traceability

Traceability is critical in the food and beverage industry, especially nowadays, when many companies must comply with the FSMA 204 traceability rule. MES will significantly streamline inventory management, helping you comply with food safety regulations.

Better Communication

MES transfers information to the right place, at the right time, and to the right people. Its level 3 position in the ISA model described earlier makes it a great mediator between the ERP and production. This means that no valuable information will be lost in the manufacturing process.

Cost-effectiveness and Efficiency

Having implemented MES software, you will no longer spend extra time on manual data management. It will provide you with more resources for other tasks that require your time. So, MES integration leads to optimized time management and better efficiency.

Continuous Improvement

Continual improvement is an essential part of the food and beverage manufacturing process. Food companies will find growing and maintaining consistent quality easier with better transparency and optimized data exchange.

Overall, the manufacturing execution system has many benefits, and each food manufacturer can find even more, depending on their request. Considering the pros and cons of MES will help make an informed decision.

Challenges for Implementing MES Systems

While MES is an efficient and beneficial solution, you may still encounter obstacles, and we consider it fair to let you know what can happen so you are fully aware.

Costs

Firstly, MES implementation can be costly, especially for smaller businesses on a tight budget. MES software requires significant investment and a large budget for maintenance. The challenge can also include rapid changes in regulations and standards that will lead to additional spending.

Implementation Takes Time

On average, implementing MES can take up to one and a half years. The procedure includes vendor analysis, preparation, customization, and other steps. You need to be patient and take your time to incorporate a solution.

Adapting and Customization

The manufacturing execution system must be fully adjusted to your food business, which demands time, money, and professional expertise. Adapting to current operational needs will also require some effort.

The main MES implementation challenges can be costs, time, and intricate implementation processes. Please remember the list doesn’t aim to discourage you from using MES but to help you be fully prepared.

World Food Brands Implement MES

The best way to demonstrate MES effectiveness is to showcase the world’s leading food and beverage companies that have successfully implemented a manufacturing execution system and helped them elevate their business.

Top brands, such as Mars, Nestle, PepsiCo, and Conagra Brands, have successfully implemented manufacturing execution systems (MES) that have helped them improve operational efficiency, ensure regulatory compliance, and maintain their leading market positions.

This proves that incorporating MES Software is a valuable strategy for the company’s success.

Discover FoodReady MES Functionality

If you are a food manufacturer looking for an MES solution, FoodReady software can help you overcome the challenges of MES implementation and bring the best results to your business.

FoodReady cloud-based software allows authorized workers to access daily operations quickly from multiple locations. It provides instant visibility over essential aspects of food production.

FoodReady is equipped with comprehensive monitoring tools and integrated IoT devices that will allow you to control manufacturing processes at different supply chain stages. Monitoring and analytics capabilities will provide cross-functional transparency and enhance data exchange.

FoodReady food safety software will ensure your food safety compliance with local and state regulations. You will also be able to enhance food traceability and meet the new food traceability rule requirements.

We greatly care about quality assurance at FoodReady, so once you implement our solution, you will benefit from diverse quality control and assurance features. You will also worry less about inventory management, recipe formulation, maintenance management, and other significant tools you are looking for.

FoodReady is affordable; you can find the best package with easy implementation and quick training. Our user-friendly interface lets you start working with the MES faster than expected.

FoodReady goes beyond food safety software and combines the functionality of the MES you are searching for. Contact us, and together, we can bring your company to the next level.

Conclusion

Manufacturing execution software (MES) is an indispensable tool for overseeing the whole manufacturing process, from raw materials to finished goods.

Of course, as with any other comprehensive solution, it requires time and money to start working with, and you may postpone implementing it into your business due to high costs, system complexity, preparation procedures, etc. However, MES benefits prevail over the challenges. 

The system will save you money and time, provide 100% visibility, help improve food safety compliance, optimize inventory, and manage food traceability. It’s worth a try, as MES will become your long-term investment in your food and beverage company development.

FoodReady software will be a perfect solution if you are looking for affordable and modern MES software. We will help you overcome your fears and the most difficult challenges. Book a demo to see FoodReady’s MES functionality in full.

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