12 MES Implementation Steps for Success
Is your manufacturing organization ready to enter the age of digital transformation? An essential step is implementing a manufacturing execution system (MES)—a software-based system that will modernize and optimize every aspect of your manufacturing operations.
Today’s manufacturing businesses need an MES to stay competitive in a digital market. The benefits are tried and true, including everything from providing real-time visibility into and control over the entire manufacturing process to reducing errors and automating workflows. And yet some organizations hesitate to implement an MES system—many because the process seems daunting.
The key to MES implementation is to create and follow a plan that sets your business up for success. By having a plan in place, and by working with an experienced MES vendor, you can reduce friction in the implementation process and reap the full benefits of the system.
What Is the Manufacturing Execution System Implementation Process?
MES implementation is the process of configuring and installing MES software into an existing manufacturing operation. It involves purchasing a license for off-the-shelf MES software, customizing it to fit the unique needs of a production line, migrating manufacturing data, connecting the system to other enterprise applications, and training employees to use the new system.
Understanding the steps of the MES implementation process before jumping in headfirst is crucial to mitigating risk, doing due diligence, and seeing MES success.
How Long Does the MES Implementation Process Take?
The MES implementation timeline varies significantly based on the software itself (automation level, size, customizations, on-premises vs. cloud-based, etc.) as well as the production line itself. But on average, implementation and onboarding takes about 8–12 weeks.
Your mileage may vary.
What Are the MES Implementation Steps?
A successful MES implementation requires long-term commitment, careful planning, and strategic decision-making. And while the process will look different for every organization, the typical steps remain the same. Here, we take a bird’s eye view of the MES implementation process so you can get a better idea of what it might look like for your manufacturing organization.
Step 1: Define Clear Objectives & Expectations
Before diving into the MES implementation process, it’s important to conduct an audit of your existing manufacturing processes and, based on what you find, define clear objectives and expectations for the new MES. In other words, you have to plan out exactly what you want to accomplish so you can make sure you actually accomplish it.
Don’t approach this part alone. Get input from key stakeholders—IT personnel, production line managers, end users, executive-level decision-makers—to identify overall goals.
Step 2: Build an Internal MES Implementation Project Team
It’s time to create the A-team. Build an internal project team that will lead the entire MES implementation process. This team should consist of at least one person with decision-making power as well as several employees who are deeply familiar with the everyday production line and the needs of the factory floor.
From this team, choose a project leader who will serve as the main point of contact with the external implementation team (aka the MES vendor).
Step 3: Create an MES Implementation Schedule
Working with the MES vendor, your project team can now start building an MES implementation timeline and roadmap.
How long is the process expected to take? What are the key milestones to note? Create a schedule that will serve as a guide for the MES implementation process. This timeline will let project managers and executives know when to expect testing, when to start training employees, and when the new MES system should be completely rolled out.
Hint: Remember those goals and expectations laid out in the first step? Use those as a foundation. Make sure your project plan and schedule leads to your desired outcomes.
Step 4: Configure the MES Application to Project Specifications
Configuring the MES application will in large part be completed by the MES vendor based on your project specifications.
Your MES implementation team—as well as executives, department heads, operation managers, floor supervisors, and other stakeholders—will meet with the vendor’s implementation team to outline requirements. This meeting is your opportunity to present ideas for specific changes you want to make to the software. Are you looking for certain compliance features? Do you want to visualize acquired data in a certain way? Speak up!
As part of the configuration process, the vendor will contextualize and migrate data, customize the off-the-shelf MES software, and set up an initial testable version of the MES.
Step 5: Test the Pilot Version of the MES
The hard work is done. Now, you get to play with what the vendor has created.
Testing the pilot version of your MES will likely take place in a sandbox, where the system can be set up so that you can virtually test its capabilities, functions, and features. Your MES implementation team will be able to examine what work has been done, discuss anything you want to change, and make sure the MES is ready to integrate with your factory floor.
Step 6: Revise & Adjust the Configuration Based on Feedback
Based on your feedback, the vendor will revise and adjust the MES configuration. When it’s ready for you to view again, you can make sure everything is programmed properly, the dashboard has what you need, and all your expectations are met.
Then, it’s wash, rinse, and repeat until the MES is up to par.
Step 7: Train Employees on the MES
Implementing an MES into your production line will not only change the technology your employees use (obviously) but also change previously established workflows and processes (not as obvious). Employees at all levels will likely have questions and concerns, and everyone will need to adapt to change.
Develop a comprehensive training program to ensure your workers are ready to use the MES and prepared for all the changes it brings. Train employees based on their role to make sure each MES user understands how to use the system.
When your employees are onboarded and the system is ready to go, you can start rolling it out.
Step 8: Deploy the MES to the Initial Site
A journey of a thousand miles begins with a single step, right? The best approach is to gradually integrate the MES, starting with one machine, a specific production line, or a single area of the factory. This small-scale method allows for real-world testing, reduces the impact of any potential issues on overall production, and makes it easy to fine-tune the system before deploying it throughout all your operations.
Step 9: Rollout the MES to Other Areas
Once the initial site is green lit, you can gradually roll out the MES to other areas, production lines, machines, and departments. Taking this phased approach has the same benefits as in Step 8—in other words, you minimize disruptions and make it easy to troubleshoot problems.
Continue rolling out the MES in phases until your entire factory floor is covered.
Step 10: Integrate the MES with Other Digital Systems
After successfully deploying the MES, it’s time to integrate the software with other existing business systems, such as enterprise resource planning (ERP) systems. These systems should work together seamlessly and without disrupting overall operations, so bring up any issues to your MES vendor immediately.
Step 11: Scale the Solution
When the MES is deployed and integrated with your other digital systems in one facility, you can scale the solution as needed to handle other factories across your manufacturing organization.
This process should be ongoing. As your business grows and evolves, so should your MES.
Step 12: Monitor & Optimize the MES
What is your MES return on investment (ROI)? Have you accomplished the goals and expectations you defined in Step 1?
Create robust monitoring workflows to track key performance indicators (KPIs), regularly review and refine processes, and identify areas where you can optimize the MES to maximize the benefits of the system.
Streamline, Optimize, & Automate Manufacturing Processes with an MES System from CAI
At CAI, we create innovative, production-oriented software to help our customers across a variety of industries streamline business processes and optimize their manufacturing environment. Our goal is to provide you with industry-leading solutions that improve your daily operations, all with excellent service and support.
Whether you are looking to automate production, increase your return on investment, reduce costs, or streamline operations, we can help. With our MES applications and access to our expert team, optimizing your manufacturing processes is easier than ever.
Contact us today for a free consultation.