In today’s world of highly customized production, short lead times, and high product variety require one thing above all: transparency in the production process. Our latest project demonstrates how the structured introduction of a Manufacturing Execution System (MES) ensures exactly that.

INITIAL SITUATION

Through our structured approach and experience from numerous projects, we contribute significantly to the successful implementation of MES systems. Our customer invested in a new batch-size-one production system (storage → saw → edge banding) with an integrated sorting buffer.

• After the sorting buffer, the part flow was split into different material flows depending on sorting criteria.
• The shift to batch-size-one production enabled significantly shorter lead times but also created a greater demand for transparency and traceability of every part throughout the process.
• To deliver this transparency, a Manufacturing Execution System (MES) was specified and introduced.
  

• Creation of MES Requirements Specification
• Development and description of all relevant production and logistics processes to be mapped.
• Specification of MES requirements and functions.
• Clear delimitation of MES scope from other systems (ERP, CAD/CAM).
• Definition of the integration concept into the existing software landscape.

• Supplier Selection
• Screening of suitable MES providers.
• Conducting supplier discussions to clarify technical and functional capabilities.
• Comparison and evaluation of offers based on functionality, scalability, and cost.

• Development of the Final Functional Specification
• Detailed coordination of MES functions to be implemented.
• Specification of sorting criteria in line with customer requirements.
• Development of job documents (work papers, labels, monitor, and tablet displays).
• Coordination of transfer and feedback points for seamless process integration.

• Implementation
• Establishment of project management with clear structures (regular meetings, defined responsibilities, project plan with milestones).
• Development of interfaces to ERP, CAD/CAM, and other systems.
• Support in production organization, including:
• Creation of work sequences per part family.
• Capacity planning and production batch formation.
• Lead time scheduling.
• Buffer dimensioning and material flow design.
  

• Real-time monitoring and control of production across all areas.
• Complete transparency: the position and status of each component is always known and traceable.
• Achievement of short lead times in variant-rich, batch-size-one processes.
• Early detection of quality issues, enabling proactive interventions.
• Efficient resource utilization and reduced waste.
• Structured approach and neutral process definitions, ensuring sustainability beyond implementation.
• Clear project management with defined milestones and responsibilities.
• On-time and on-budget delivery thanks to proven methodology.

Through our structured approach and long-standing experience from numerous MES projects, we provided the foundation for a successful implementation. The result: a system that delivers transparency, efficiency, and reliability, helping our customers unlock the full potential of batch-size-one production.