Introduction
An MES, or Manufacturing Execution System, is a fundamental element in the process of digitisation of industrial plants. Nowadays, using such fundamental solutions that increase the modernity of the entire manufacturing plant is almost a necessity if an entrepreneur aims to achieve business success.
The primary role of an MES system is to record and analyse data in real time from all stages of production. As we all well know, data is currently the most valuable currency. However, if you want the collected information to be reliable and bring value to your business decisions, you should consider implementing a tailor-made MES system. Why? You will find the answer to this question in the article below!
Why are customised MES solutions crucial?
Our main goal, as an experienced provider of MES systems, is to thoroughly understand the specific requirements and business objectives of each manufacturing plant. All companies have their own specific processes and challenges that require a dedicated approach. Customised MES solutions enable a precise analysis of the organisational structure, identification of key areas for optimisation, and adaptation of the system to the specific needs and goals of production.
By thoroughly identifying needs, we can ensure the flexibility and scalability of our MES system. This means that we not only adapt to the client’s current requirements but also anticipate potential changes and company growth, enabling a smooth adaptation of the system to evolving needs.
It is also worth mentioning that off-the-shelf MES systems, although they are an attractive solution due to their speed of implementation and lower prices, often encounter limitations that can significantly hinder increasing production efficiency.
Off-the-shelf solutions are generally designed to be universal, which means they do not always meet the specific, individual requirements of a particular manufacturing plant. These limitations can lead to low production efficiency.
Additionally, companies using off-the-shelf solutions often face the problem of adapting to changes in the production process. These solutions can be rigid and difficult to modify, making it hard to adapt them to the evolving needs of the enterprise.
In contrast, our individual MES solutions offer flexibility, allowing the system to be adapted to current and future production requirements. As a result, we provide our clients with not only effective but also sustainable solutions that grow alongside their enterprise.
Long-term monitoring of electricity consumption provides essential data on which advanced strategies can be developed. Their goal is the rational management of energy costs, forecasting needs, and avoiding unnecessary expenses.
Analysis of enterprise requirements
When designing a customised MES system, the most important stage is the analysis of the requirements and goals of the enterprise for which the individual solution will be created. This phase consists of two steps – an audit and defining business goals (if the company has not specified them).
Internal and external audit
The primary aim of the audit is to gather information about the current condition of the company. It is beneficial for it to be conducted not only by one of the enterprise’s employees but also by an external consultant. This way, you will get a complete picture of your company’s state.
The key aspect around which the audit should focus is all the processes taking place on the production line. This will provide you with information on which areas in the plant require the use of a tailor-made MES system.
Defining business goals
Purchasing an individually tailored MES system is an investment. Therefore, it is worth writing down short- and long-term goals at the very beginning that this investment will help achieve. Minimising waste, shortening delivery times, or improving the flow of information between employees? Thanks to the data analysed by the MES system, you can effectively work on these aspects (and this is just a fraction of the possibilities that our customised solution offers).
Designing a tailor-made MES system
A customised MES system means that your company uses those modules that will bring the most valuable information about the condition of the production line. By choosing to cooperate with iPLAS, you can count on the support of our experts, who will advise which functionalities of the MES system will work well in your company, and which are not worth using at a given stage of the enterprise’s development.
The system offered by iPLAS uses plugins that are adapted to many data sources. These can be:
- OPC DA servers, both via COM and DCOM interfaces,
- OPC UA servers,
- any SQL databases (Oracle, DB2, Informix, MSSQL, MySQL, PostgreSQL, SQLBase Gupta),
- MODBUS RTU, MODBUS TCP plugins,
- MQTT protocols,
- any TXT, CSV, XML text files,
- XLS, XLSX spreadsheets,
- SOAP and REST Web services.
Implementation and testing
After designing a tailor-made MES system for your company, the moment comes to implement the solution in the industrial plant. What should this process look like?
System implementation
Our approach to MES system implementation is simple – we want it to take place quickly and effectively. After programming the solution for a specific company, we proceed to install the system at its premises. We check if everything is working correctly and move on to the next, extremely important phase, which is testing.
iPLAS experts will also provide the necessary training for all employees. We will explain how to use the MES system and provide expert support, as we understand that learning a new solution is time-consuming and additional questions may only arise after some time.
Testing and optimisation
The next key stage is testing the MES system in real-world conditions. We cooperate with the client to ensure that the system works as expected, identifying and eliminating potential problems.
Examples of good practices and tools for monitoring electricity consumption – what can be done independently, and when is it worth using the help of specialists?
A good idea for optimising energy consumption in an enterprise is a lighting audit. Often in industrial plants, companies still use outdated lamps that consume huge amounts of electricity. Modernising lighting to LED can reduce energy consumption by up to several dozen percent! Another good solution in terms of lighting is investing in automatic controllers. Sensors can be programmed to turn on lights in specific areas at selected times and turn off lamps in rooms where there are currently no people.
It is worth opting for specialist help when you want to invest in an advanced energy consumption monitoring system integrated with all devices in your enterprise. iPLAS is such a system, enabling control over every area of the production line. The solution is tailor-made to the needs of a specific plant, so energy consumption monitoring is just a fraction of its capabilities. You can have access to advanced data regarding machine status, overall production efficiency, material consumption, as well as many other parameters crucial to the company.
The future of customised MES systems
Considering current trends in the technology industry, several conclusions can be drawn regarding the future of individual MES systems for industrial plants.
Intelligent data analysis
Customised MES systems will increasingly offer advanced data analysis, using artificial intelligence to identify trends, forecast failures, and optimise production processes based on the collected information.
Internet of Things (IoT)
Integration with the Internet of Things will be crucial for individual MES systems. IoT sensors and devices will enable real-time data collection, allowing for even more precise production monitoring and response to current challenges.
Cybersecurity
Given the growing cyber threats, customised MES systems will place even greater emphasis on security. Modern encryption, authorisation, and monitoring methods will help protect data from unauthorised access.
In the context of the future, one of the greatest advantages of a tailor-made MES system is its flexibility and the ability to adapt the solution to the growth that accompanies the company. The iPLAS team of experts, responsible for implementing the system in your plant, will be at your disposal if you feel that it requires an update or the addition of new modules.
Using a customised MES system enables a manufacturing company to collect the most important data, which is then visualised in a preferred way. It is thanks to this information that owners and managers can make key decisions for the enterprise quickly and accurately.
We help manufacturing plants grow and optimise processes because we believe that the potential for the growth of any company lies in reliable data!
