11. Manufacturing Execution System

What tasks does an MES perform in equipment management today?

Key MES tasks in equipment management include:

Real-time Equipment Monitoring & Control
Maintenance Management: maintenance scheduling and fault alerts
Production Scheduling to optimize machine utilization
Quality Management related to equipment operation
Data Collection & Analytics: KPI and OEE monitoring

These tasks help manufacturers improve equipment efficiency, reduce downtime, and optimize production processes.

How does an MES collect equipment data directly?

An MES collects equipment data through direct connections to PLCs, sensors, HMIs, or SCADA systems.
Industrial communication protocols such as OPC UA, Modbus, and Ethernet/IP are used to acquire real-time operational data, machine status, and production parameters for monitoring, analysis, and optimization.

How does an MES handle legacy machines without PLCs?

For legacy machines, MES solutions typically use:

External sensors or IoT gateways
Retrofit kits to convert analog/digital signals into digital data

This approach enables MES to monitor machine status, track output, and analyze performance without replacing the entire machine.

How is equipment data accuracy ensured in an MES?

MES data accuracy is ensured through:

Direct data acquisition from PLCs, sensors, and HMIs
Data validation mechanisms, error checking, and real-time time synchronization

This ensures reliable data for monitoring, KPI calculation, and equipment performance optimization.

Which parameters are used by MES to calculate OEE?

MES typically calculates OEE (Overall Equipment Effectiveness) based on three core parameters:

Availability: The ratio of actual operating time to planned production time
Performance: A comparison between actual production speed and the machine’s designed speed
Quality: The ratio of good products to total output

By combining these parameters, MES provides a comprehensive assessment of equipment effectiveness and supports continuous improvement initiatives.

How does MES support equipment maintenance management?

MES supports equipment maintenance through:

Preventive maintenance scheduling based on calendar time and operating hours
Predictive maintenance alerts derived from sensor data and machine performance trends
Maintenance history tracking to analyze failure causes and optimize maintenance strategies

As a result, MES helps reduce downtime, extend equipment lifespan, and improve overall production efficiency.

Can MES analyze machine downtime root causes?

Yes. MES records and analyzes machine downtime events based on data from PLCs, sensors, and operational logs.

Downtime reasons are classified by machine, process step, or operational error
This enables manufacturers to identify bottlenecks, improve processes, and reduce unplanned downtime

How scalable is MES when the number of machines increases?

MES systems are designed with an open and scalable architecture, allowing additional machines, production lines, or manufacturing areas to be added without impacting overall system performance.

Scalability ensures continued real-time data collection, performance monitoring, and maintenance management for all newly added equipment.

How does MES integrate with ERP or SCADA systems?

MES integrates with ERP systems to synchronize production, inventory, and order data via standard interfaces such as APIs or database links.

When connected to SCADA, MES collects real-time operational data and equipment status, enabling advanced monitoring, analysis, and production optimization.

Does MES implementation affect ongoing production?

No. MES implementation is typically carried out in phases to avoid production disruption.

The system can collect data in parallel with existing operations, enabling monitoring, analysis, and optimization without reducing production performance.

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11. Manufacturing Execution System

IDEA GROUP

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About IDEA

Service

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News

Training

Products

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