MES Software: The Backbone of Manufacturing Automation
MES software is crucial for any production line. It constitutes the core of manufacturing and factory automation solutions. Providing real-time production tracking, industrial automation, and data management, MES software forms the backbone of all manufacturing units. Over the years, we’ve witnessed the transition from manual processes to spreadsheets, from spreadsheets to off-the-shelf MES software, and from off-the-shelf software to custom software. This evolution has significantly improved the operations of many companies.
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In today’s world, it’s all about automation. The faster you can access and analyze information, the more efficiently your production can perform. No manufacturing unit today relies on manual information—it’s too slow, often faulty, and unreliable. The second stage, where people use spreadsheets, is equally problematic. Most companies now use MES systems, readily available in the market and used by similar manufacturing companies.
The reason people opt for off-the-shelf MES systems is because they are readily available, solve basic manufacturing problems (common to all MES systems), and are used by competitors or similar companies. However, over time, most manufacturing units realize the limitations of off-the-shelf software. Customization can enhance certain processes. Standard operating procedures (SOPs) shouldn’t be based on how the software works. Instead, your software should adapt to your SOP.
With a custom MES system, you can create tailored MES solutions for factories, including production monitoring, real-time production tracking, custom workflow management, and much more. While standard off-the-shelf MES software requires shop floor data collection, automation and IIOT can provide real-time data with custom MES software that collects shop floor data every 30 seconds or a minute without human intervention. As companies grow, they often find that their existing systems no longer meet their requirements. A custom solution becomes the only option. No ready-made, off-the-shelf software can fulfill all the needs of your manufacturing floor.
Over the next few years, many companies will adopt automation on the factory floor. With IIOT solutions, your software will collect data automatically from various sources, accumulate information, and present it in a format that is easy to understand and provides data-driven decision-making capabilities. From lean manufacturing with MES to production lifecycle management tools, every part of your system will be custom-created to meet the specific needs of your business.
The 3 Stages of Custom Software Development and Failures
MES custom software development is often faced with hurdles in many organizations, especially ones that have no standard operating procedures. A manufacturing system that is well-organized and has standard operating procedures will have a clear idea of how the systems are meant to work and can create a workflow for software. Without a clear workflow or an agreement on the workflow, it is difficult to create software. More than 10% of all companies fail to take off with a software development project due to a lack of agreement on how the MES should work, what workflows are required, and how each of the workflows should work in tandem with each other.
The second phase, where most companies fail in terms of custom MES development, is when the base implementation of the technology is completed but not all custom workflows are in place and tested. Some companies either run out of budget during this phase, leaving part of the software incomplete. Then there are operational disruptions and disagreements among management or shop floor workers on the workflow implementations, which lead to delays. Over 90% of all custom MES software development fails during this phase. Additionally, there are companies that don’t realize the benefits of the software and can’t see the return on investment. Small manufacturing units and operations will find this very relatable.
Only 10% of all custom software developments for MES are known to be successful. These are often large companies with large operations. They have tested the solutions over a period of time and have sufficient information to see ROI. Most of these companies have implemented solutions on time and on budget.
Key Factors That Ensure a Successful Custom MES Software Development
Various factors determine how successful your MES software integration will be. Key factors include your existing system, possibilities of easy migration to a new system, or integration of new processes into your existing system, the experience of the company, and the scalability of your existing MES system. Most MES systems are scalable to some extent. If your MES system can be used as a core with additional custom-created modules to your existing system, companies could reduce costs on developing additional custom modules. Factors like the software development company you choose and their experience in the existing software and systems play an integral role in the success of your project. Delays due to inefficiency and lack of knowledge about the current system may incur costs over time.