14 Steps For A Successful MES Implementation
There are several risks involved when deploying an MES system just like with any other complex software. But MES cannot be compared to other technologically based system solutions. MES fundamentally alters business processes and as a result, has a significant impact on end users’ day-to-day operations.
Gaining feedback from every department that will be impacted by the adoption of a MES system is crucial to its effective deployment, as is successful change management, which is a key element of aligning technology, people, and business processes.
For an MES application to be properly implemented, systematic planning is necessary. The objective is to create a coherent deployment sequence based on the existing processes. This relies on how the system connects the different steps.
This post highlights 14 steps you should consider when designing an easy setup MES software so that you can have one that functions and satisfies your business needs.
- Examine the necessity for an MES and list the main issues and areas that need improvement on the plant floor. Alternatively, create a business case analysis.
- Discuss and define the MES feature scope with project stakeholders like internal IT, automation unit, and shop floor executives.
- Create a thoroughly researched user requirements. Include external MES specialists who can manage all external interfaces if the need arises.
- Name the vendor and the software. In this stage, the final customer, vendors, and any participating companies negotiate terms, pricing, and any applicable laws.
- Prepare a gap analysis with the existing and new external interfaces, a solution strategy, a project schedule, including a plan for the pilot rollout and a complete rollout of the MES, resource planning, a project budget, risk analysis, and a training plan.
- Establish the new system architecture and gain a thorough understanding of the schedule for the external interface’s availability.
- Decide how the system will be tested, particularly during integration testing, both before and after deployment (in a test environment) and in a production environment. Ensure that the production test includes end-users. End-user feedback is very helpful during testing since they are familiar with the process and can provide insights based on problems they have encountered in the past.
- Create a pilot application, evaluate its viability, and check its interface with the shop floor and ERP.
- Create the MES application, then perform a full test environment validation. Make sure to have representatives from the shop floor on the MES software validation team.
- Deliver training, introduce the tested MES application into the test production line, integrate with external systems, watch how the new MES system behaves, and resolve any potential problems.
- Execute the deployment and training plans for the remainder of the site after the MES application test has been validated in the pilot production line.
- Monitor and offer assistance with MES solutions.
- Alter your MES when your business evolves, such as when you acquire new items and machines, train new employees, launch new projects, etc. Plan for the changes in your business and take them into account when deploying MES.
- Decide when to launch your MES installation. Production facilities undergo this every six months. For instance, if you have five production facilities, it will take two years and six months to implement MES.
A properly implemented MES will typically lead to certain cost savings opportunities, such as a shorter workweek and more financial rewards. Establish the cost of addressing defects, such as scrap products that limit production, before deploying an MES to determine the ROI.