MES: How one system can help manufacturers cut emissions and boost efficiency

Manufacturing companies have always had a strong focus on increasing productivity and efficiency in their operations. With many parts of manufacturing processes being digitized and automated, data volumes are increasing. However, data is often siloed, making it difficult to process and use to make operations more data-driven. At the same time, manufacturers face mounting pressure to account for their environmental impact and provide traceability for all parts of production.

One of the most powerful tools to achieve these dual outcomes is a manufacturing execution system or MES. An MES is a comprehensive system for planning, executing and monitoring production processes. A digital MES collects a wealth of production data in real-time, making it possible to control the manufacturing plant to ensure it functions efficiently, people work safely, machinery is used optimally, and production is monitored to meet the highest possible quality standards.

Enhancing decision-making with MES data insights

While all manufacturing companies have some form of an MES function, they are not always digital. Some manufacturers still rely on paper-based systems or Excel spreadsheets. Investing in a digital MES has numerous benefits, not the least of which is accessing real-time data for more informed decision-making.

With an effective MES, it is possible to analyze production data to optimize manufacturing in real-time. Today, it is also possible to use artificial intelligence (AI) and machine learning to interpret the data effectively based on planning, quality and raw material availability.

An MES can provide information on the status of production at each stage, stock levels and the quality of products. For example, machine learning algorithms can be used to analyze production data and identify patterns and trends, allowing manufacturers to anticipate and address potential problems before they occur. Different types of visual technology can also automate quality checks, reducing the need for manual inspection and improving product quality. It can also identify production bottlenecks to increase efficiency. Despite the many benefits of MES, there are still manufacturing companies that do not have a modern MES in place.

Driving ROI-led business outcomes

Here’s why they should consider one. An MES can provide very large efficiency gains, and it is not unusual for a system to “pay for itself” within a year. As more and more things become connected with sensors built in easily and inexpensively, there are even more benefits to be gained, such as the system being able to see exactly where different products are located. It is also possible, for example, to identify where a tool is located in a workplace. Another example is embedding sensors in protective equipment to track employee movements, with alarms in place to warn individuals if their safety is at risk during transportation or when moving heavy machinery or materials.

Advancing sustainable manufacturing

However, the benefits of an MES are not restricted only to production. With many manufacturing companies facing stricter regulations around environmental impact and reporting, an effective MES is an important piece of the puzzle to reliably meet new and evolving requirements.

According to the World Economic Forum, one-fifth of the world's carbon emissions come from the manufacturing and production sectors. The ability to collect and analyze data is critical to achieving climate goals and reducing the environmental impact of manufacturing.

An effective MES can provide real-time data on energy consumption, enabling the business to identify potential energy savings. It can also help reduce residual products and waste and track manufacturing from raw material to final product, which can result in significant environmental gains. Automating compliance reporting also provides more efficient and reliable outcomes.

There are many reasons why manufacturing companies need to move toward becoming more data-driven. Most importantly, data helps businesses become better at what they do. To continue to streamline their operations and keep up with regulations and requirements, more comprehensive and systematic management is needed.

If your data is currently saved in Excel sheets or on paper, a good first step is to organize the production process and digitize existing data. With better control in place, more advanced functions can then be added, such as quality and process management, maintenance, scheduling, resource allocation, and much more. An MES can then ensure the right information and insights are made available to all relevant parts of the business.

With a digital MES, you can make insights-driven business decisions and improve performance across the supply chain, empowering you to actively advance your ESG goals.

If you’d like to know more about choosing and implementing an MES and the tangible business outcomes it can help your organization achieve, contact me.