When it comes to optimizing manufacturing operations, especially on the factory floor, the most important lesson is using the right tool for the right job. Many manufacturers look to a Manufacturing Execution System (MES) as the first solution to this problem. After all, MES is designed to control, monitor, and track factory floor operations. It’s a tool built for complex manufacturing environments, where the need to track every detail—from raw materials to finished products—requires comprehensive oversight. But for many manufacturers, MES is not be the best starting point.
While MES systems are powerful, they are also giant monoliths that require substantial resources, specialized personnel, and significant time to implement and maintain. MES implementations often demand months of effort, large capital investments, and detailed customization to fit unique factory needs. Furthermore, the user experience is often cumbersome, requiring extensive training for employees to fully understand how to operate it.
As a result, while an MES system promises enhanced control and visibility, its complexity may not always offer a proportionate return on investment (ROI), particularly for small to mid-sized manufacturers or those with less complex production needs.
The Misconception: Is MES the Right Place to Start?
The common misconception is that an MES is where manufacturers should begin their journey toward operational excellence. After all, the MES offers advanced features like production scheduling, tracking work-in-progress (WIP), resource management, and real-time data collection. In theory, an MES gives manufacturers total control over every step in the production process. However, for many, this level of control may be unnecessary—or, at least, it may not be the most efficient first step.
Instead of diving into a full-scale MES, manufacturers may benefit more from starting with a simpler solution. MES systems are often standalone platforms, or they can be integrated into Enterprise Resource Planning (ERP) systems, adding another layer of complexity. The integration between MES and ERP can streamline processes, but it can also complicate things further for manufacturers who don’t yet have visibility into basic operations. Before committing to an MES, it’s critical to ask: do you really need this?
The Pros and Cons of MES Systems
One of the biggest advantages of an MES is its ability to handle complexity. In industries like pharmaceuticals, where traceability is critical, MES is often essential. Regulatory compliance in these fields demands minute-level detail about every product’s journey through the factory, making MES indispensable for ensuring that nothing falls through the cracks. In these cases, MES delivers real value by reducing errors, ensuring compliance, and optimizing processes.
But for many other industries, MES may be overkill. If your factory floor doesn’t require such a high level of detailed tracking or doesn’t face stringent regulatory requirements, an MES can feel like using a sledgehammer to drive a small nail. Most manufacturers do not need that level of granular visibility or control to achieve significant improvements in efficiency, uptime, and productivity. In fact, even large automotive manufacturers, despite having complex production environments, may find that the level of detail offered by an MES is excessive.
Another issue with MES is that they often try to stretch their functionality beyond what they do well. While MES systems excel at providing a detailed overview of production processes, they are not designed to handle every aspect of manufacturing operations. Over time, manufacturers may attempt to use MES to solve problems it wasn’t intended to address, leading to a system that is bloated and does many things poorly.
Where Manufacturers Should Start Their Optimization Journey
For most manufacturers, the optimization journey begins with a simple request: “I need to understand what’s happening on my factory floor.” This is where many manufacturers mistakenly believe that an MES is the answer. What they actually need is real-time visibility into production processes, machine performance, and key metrics like downtime and cycle time. The goal should be to get immediate insights into what’s working and what isn’t—without the complexity of an MES.
Rather than jumping into an MES, manufacturers should consider starting with a production monitoring system that focuses on providing real-time data, without the complexities and overhead that come with a full-blown MES. This allows manufacturers to gain insight into key areas of the factory floor quickly, make improvements, and build from there. Starting simple enables a continuous improvement mindset where you can think big and move fast.
The Advantages of Mingo Smart Factory
This is where solutions like Mingo Smart Factory offer an attractive alternative to a traditional MES. Mingo provides core MES functionalities such as real-time production monitoring, data collection, and resource management, but without the overwhelming complexity and cost associated with full-scale MES implementations. Mingo allows manufacturers to incrementally implement the tools they need to improve visibility, reduce downtime, and boost capacity—all without over-investing in a system that may ultimately offer diminishing returns.
One of the biggest advantages of Mingo is its modular and flexible approach. Manufacturers can start with the most basic functionality—such as tracking downtime, monitoring cycle times, and collecting real-time data from machines—and expand as their needs grow. This incremental approach allows manufacturers to implement a solution quickly and begin seeing ROI almost immediately. Rather than waiting months for an MES to be fully integrated and functional, manufacturers can deploy Mingo in a matter of days and begin gathering the insights they need to make impactful changes.
Mingo also embodies the “start simple, think big, move fast” mentality. It gives manufacturers the ability to begin small, solving immediate problems like downtime and bottlenecks, and then build out more advanced features as needed. By focusing on the right tool for the right job, Mingo helps manufacturers improve Overall Equipment Effectiveness (OEE), increase throughput, and optimize factory performance—without the complexity and bloat of an MES.
A New Era of Manufacturing Solutions
In today’s fast-paced manufacturing environment, the old monolithic solutions like MES are being replaced by more agile, modular, and efficient systems that focus on solving specific problems quickly and effectively. Manufacturers no longer need to invest in massive, complex systems just to get real-time insights into their factory floors. Instead, they can use solutions like Mingo Smart Factory to gain visibility, make improvements, and unlock capacity without being weighed down by unnecessary features and complexity.
So, if you’ve been considering an MES to improve your factory floor operations, it might be time to rethink your approach. Welcome to the new world of manufacturing optimization, where the right tool for the right job means fast implementation, quick insights, and measurable results. Mingo Smart Factory offers the flexibility and functionality you need to compete in today’s market—without the overhead and complexity of traditional MES systems. See how it works or check out a demo today.
