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Impact of an MES on Output

A manufacturing execution system (MES) aids in streamlining manufacturing operations within a facility through real-time communication of information across all parts of the production process. Essentially, an MES is a shop floor control system, transmitting data and critical pieces of information as it happens between manufacturing and other company functions.

Among the many benefits of an MES, increased output means manufacturers can produce more in less time. But, how exactly does an MES increase production output?

Professional Studies on the Impact of an MES

Most manufacturers who’ve implemented an MES likely will tell you the positive impacts it has had on production – specifically output. As each application of the software looks a little different, looking at data from third-party research organizations is equally as helpful in illustrating impact.

Manufacturing Enterprise Solutions Association (MESA International) has conducted numerous studies regarding MES implementation. As an independent authority on manufacturing best practices, MESA provides insight into the industry and educational resources regarding improving operations throughout the manufacturing process.

When studying the effects of MES implementation, MESA found that output rose by 15% vs. pre-implementation. Additionally, first-pass yield increased an average of 14%. When thinking about large manufacturing operations, those increases are substantial. However, it’s important to note the reasons why output tends to increase so significantly with the implementation of an MES solution.

MES software eliminates much of the need for manual paperwork and correspondence as it communicates important updates to and from the shop floor in real-time. Such updates include changes in personnel or raw material availability, information regarding machine maintenance or issues, and the shifting around of work orders to accommodate these changes. Because information is shared in the moment between the shop floor and other departments, organizations save time manually tracking and communicating this to each other.

In addition to saving communication time, the real-time visibility of production KPIs that an MES provides allows manufacturers to better schedule production to limit downtime of both machines and personnel. Having to stop operations because a machine needs to be cleaned or someone calls in sick is harmful to output. So, using an MES helps to schedule maintenance during downtime and shifts workloads around in cases of employee absence. The same applies when raw materials needed for a run are delayed. An MES automatically adjusts schedules when this happens and moves around or freezes work orders to limit the amount of time during production hours that a machine is idle.

Another way an MES helps with output is by reducing rework and scrap due to errors in the manufacturing process. The software closely monitors production and alerts management of defects in real-time. Some versions, such as IMCO-CIMAG MES, also provide up and down traceability of materials, personnel, machines, or tools. This traceability allows manufacturers to easily and quickly identify trends in defects and trace them back to certain production variables. Traceability, in combination with the in-the-moment communications of defects, means less wasted time correcting errors that take longer to identify and trace.

Overall, an MES removes a lot of manual tracking and scheduling needs and increases transparency between the shop floor and other departments, allowing for machines and operators to complete work orders more efficiently. Greater efficiency of operations and less downtime of machines means more production, and thus – higher output.  

 

IMCO Software MES inside the new factory manufacturing electrical cables using mes for increased output production header

IMCO-CIMAG MES – Helping Manufacturers Grow Output

Not all MES solutions are created equal. At IMCO, we pride ourselves on creating an MES software that goes beyond what others provide to give our customers even higher levels of production visibility and control over output. The industries in which we’ve helped manufacturers improve range from automotive or food and beverage to plastics. No matter the application, IMCO-CIMAG continues to transform operations across industries – increasing output, maximizing efficiency, and increasing profitability.

One collaboration we are most proud of is our work with Pyroalliance, a leading manufacturer of pyrotechnic and mechanical equipment. Before implementing IMCO-CIMAG MES, Pyroalliance experienced issues with the reliability of its production and delays in production due to outdated communication practices. This is an organization fulfilling over 2,000 work orders each year. By implementing IMCO-CIMAG MES, Pyroalliance was able to take a previously outdated process of transmitting information via paper and switch to a digitized and instant communication process, increasing responsiveness and reliability of their production schedules. Wanting this information to be accessible throughout their expansive shop floor, Pyroalliance also now provides tablets to operators, so that relevant information they need travels with them.

Overall, Pyroalliance saw huge savings in time due to the real-time communication and increased responsiveness the MES provides. By adjusting work orders instantly when issues arise, they are now able to limit unscheduled downtime – thus, increasing output.  

No matter the industry, IMCO-CIMAG MES brings transparency, ease of communication, and increased efficiency to the manufacturing process. Output increases due to more uptime, real-time visibility of the shop floor, and the ability to instantly alert manufacturers of needed changes to production schedules to maximize output.  Our software solution has the flexibility to be effective for manufacturers in ANY industry, and we work with our customers to ensure that it meets their specific manufacturing needs. We are happy to provide a free demo of our software solution and discuss ways to improve output in your organization – contact us today to schedule a consultation.

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