The Role of MES in Industry 4.0 | HBS

MES Software (Manufacturing Execution System): Optimizing Manufacturing Operations in Real Time

An MES (Manufacturing Execution System) is an information system used in the manufacturing industry to manage, monitor, and control production activities in real time. MES software operates between the company’s planning and scheduling level (e.g., ERP) and the on-the-ground control level (e.g., production automation). It allows for the acquisition and analysis of production data, providing detailed insights into operational status, inventory management, material tracking, human resources management, and other production-related activities. In short, MES software helps optimize operational efficiency and improve visibility and control over production processes.

 It is important to note that not all MES systems on the market are identical. The MESA (Manufacturing Enterprise Solutions Association International) has established a standard functional model, but over the years, various software providers have differentiated their offerings by adding new features and utilizing different development technologies. What are the industrial sectors where MES operates? They are diverse and feature differentiated functionalities. For example, in the food industry, MES can monitor food production, track batches of ingredients used, manage packaging operations, and ensure compliance with food safety and hygiene regulations. Additionally, MES systems can facilitate recipe management and product labeling.

With the increasing adoption of Industry 4.0 and the Industrial Internet of Things (IIoT) within plants, the agility and interoperability of Manufacturing Execution Systems (MES) have become even more strategic for managing added complexities and ensuring companies are future-proof. Industry 4.0 introduces new technologies into factories, such as smart sensors, wireless communication, the Internet of Things, digitalization, 3D printing, robotics, and advanced sensors. MES systems play a crucial role in implementing these technologies. For example, imagine placing smart sensors along a production line. These sensors collect process data and communicate with one another, but this data, by itself, doesn't provide valuable insights into production progress. This is where an MES system comes into play, using special algorithms to add value to the data and provide critical information to managers. MES systems transform the collected data into meaningful insights, enabling real-time visibility into what's happening on the factory floor.

The MES NET@PRO system is owned by Qualitas, a company with over 30 years of experience in MES and APS systems for production management. It is an advanced system for managing, monitoring, controlling, and planning production. It is the first MES system in Italy to globally manage operations according to Industry 4.0 principles, making it ideal for manufacturing companies that wish to maintain real-time control over production and ensure maximum production efficiency. The collaboration between the two Competence Centers of Impresoft Industry Solutions and Business Solutions provides a further boost to the manufacturing sector by integrating Qualitas's MES NET@PRO system with SAP Business One, implemented by HBS.

Regarding production, the system allows for real-time data collection and monitoring of progress, offering an immediate view of ongoing activities. Through dedicated dashboards, productivity indices can be visualized, enabling proactive decision-making to improve efficiency. For planning, the MES software supports both short-term scheduling, with sequencing of activities on machines, as well as medium- and long-term planning. Tools such as MRP2 (Material Requirements Planning) help efficiently manage material and capacity requirements.

In logistics, the NET@PRO system manages material traceability along the supply chain and offers advanced features for warehouse management (WMS). This ensures efficient stock management and complete visibility of material status. The integration and interconnection with production machines are fundamental aspects of Industry 4.0. The MES software enables bidirectional communication with machines according to Industry 4.0 standards and prerequisites, facilitating data acquisition and the execution of automated actions. Quality control is another area supported by the MES software. Thanks to dedicated operational features, the system provides support for quality management according to Total Quality Management (TQM) principles, enabling real-time monitoring and analysis of quality parameters. Maintenance is managed efficiently by the MES software, supporting both scheduled and on-demand maintenance. This allows the adoption of Total Productive Maintenance (TPM) principles, optimizing maintenance activities to minimize machine downtime and maximize production efficiency. Finally, the MES software integrates with other business systems, such as ERP (Enterprise Resource Planning), APS (Advanced Planning and Scheduling), and CPM (Collaborative Production Management), enabling quick and seamless data exchange between various systems. This ensures a global view and consistent data flow across the entire company.