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2025 TAIPEI CYCLE exhibition in Taipei

Manufacturing Execution System: The Key Solution for Smart Manufacturing

Data-Driven Decisions: In-Depth Analysis for Continuous Improvement​

Manufacturing Execution System: The Key Solution for Smart Manufacturing

System Overview​

MES (Manufacturing Execution System) is a core technology in smart manufacturing, responsible for monitoring, tracking, recording, and controlling the production process to ensure efficient operations with real-time responsiveness. With MES, enterprises can optimize production processes, improve product quality, reduce operational costs, and ensure compliance and traceability.

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MES System Structure

MES system follows international standards ISA-95 and IEC/ISO 62264, structured into five levels to ensure smooth information flow and enhance manufacturing efficiency：

  • Enterprise Decision Layer （Level 4）：Integrates the ERP (Enterprise Resource Planning) system, responsible for strategic planning, financial management, and resource allocation.
  • Manufacturing Operations Layer（Level 3）：The MES layer is responsible for production plan execution, process monitoring, quality tracking, and data management.​
  • Supervisory Layer（Level 2）：Includes SCADA (Supervisory Control and Data Acquisition) and HMI (Human-Machine Interface) for real-time production data monitoring and interaction with MES.
  • Control Layer（Level 1）：PLC (Programmable Logic Controllers) and machinery execute production actions and provide real-time data.
  • Equipment Layer（Level 0）：Machinery, sensors, and robots are responsible for production execution and transmitting operational data.
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MES System

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BOM/Work Order Management

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Scheduling Management

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Work in Progress (WIP) Management

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Equipment Monitoring Management (SCADA)

Core Function Modules

The MES system offers a variety of function modules, providing comprehensive production management capabilities:

  • Production Management: Real-time monitoring of work order execution, optimizing production processes, and improving delivery accuracy.
  • Equipment Management: Monitoring OEE (Overall Equipment Efficiency), scheduling preventive maintenance, and reducing unplanned downtime.
  • Quality Management: Providing SPC (Statistical Process Control) and complete quality traceability to ensure product consistency.
  • Inventory and Logistics Management: Real-time tracking of material and finished goods inventory, reducing stock accumulation and waste.
  • Data Analysis and Visualization Management: Improving information transparency through KPI dashboards and real-time monitoring screens.

MES Production Management Process

MES is responsible for Production Planning → Work Order Execution → Real-time Monitoring → Quality Inspection → Data Feedback, ensuring stable factory production and continuous optimization.

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Production Planning
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Work Order Execution
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Real-time Monitoring
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Quality Inspection
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Data Feedback

System Features

1

Systematic Management

  • Material and Inventory Management: Accurately track material in and out, optimize inventory levels, and reduce cost of inventory management.
  • Order Management: Track the entire process from order reception to production completion, ensuring on-time delivery.
  • Process Recipe Management: Standardize process recipes to ensure product consistency and facilitate quick adjustments to production parameters.
2

Real-time Production Equipment Status

  • Overall Equipment Efficiency (OEE): Real-time monitoring of equipment operation efficiency, identifying bottlenecks, and enhancing capacity.
  • Health Diagnostics: Predictive maintenance to reduce equipment failure risks and extend equipment lifespan.
  • Key Real-time Information: Provides key operational indicators to support quick decision-making.
3

Optimized Production Scheduling

  • Automated Scheduling Assistance: Automatically generates the optimal production plan based on order priority and equipment status.
  • Order and Production Scheduling: Flexibly adjust production plans to meet changes in market demand.
4

Exception Reporting and Analysis

  • Exception Reporting and Analysis: Quickly detect and report production anomalies, provide root cause analysis, and prevent issue escalation.
5

Real-time In-Process Tracking

  • Input and Output Statistics: Accurately record input and output for each process step, ensuring production data transparency.
  • Progress Management: Real-time monitoring of production progress, with early warnings for potential delays.
  • Yield Statistics: Analyze yield rates for each process step to continuously improve process quality.
6

Integrated Equipment Maintenance

  • Maintenance Checklists: Establish standardized equipment inspection procedures to ensure maintenance quality.
  • Smart Reminders: Automatically remind of optimal maintenance timing based on equipment usage, preventing over-maintenance or neglect.
7

Process Reporting System

  • Process Reporting Design: Simplify operation processes, reduce human errors, and improve reporting efficiency.
  • Production Status Control: Real-time update of production status, supporting management decision-making.
8

Energy Management

  • Electricity Usage Analysis by Time: Monitor electricity usage across different time periods, optimize production scheduling, and reduce energy costs.
  • Peak Electricity Consumption Statistics: Identify peak electricity usage, implement energy-saving measures, and avoid overload operations.
  • Contract Capacity Recommendations: Provide optimal contract capacity suggestions based on actual electricity demand, reducing basic electricity costs.
9

Customized Dashboards

  • Real-time Production Status Display: Display real-time production data on large screens or mobile devices to enhance transparency.
  • Diverse Chart Presentations: Use line charts, bar charts, pie charts, and other forms to visually display key indicators.

Advantages of MES

Implementing an MES system brings measurable production benefits:

  • Increase Production Efficiency: Through automated scheduling and real-time monitoring, reduce production bottlenecks and improve capacity by 10-30%.
  • Reduce Operational Costs: Minimize human errors and lower scrap rates by 15-25%.
  • Improve Product Quality: Leverage data monitoring and anomaly analysis to reduce defect rates by 10-20%.
  • Enhance Information Transparency: Provide real-time production data to support management decisions and improve response speed.
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UI / UX Features

MES offers an intuitive interface design to enhance user experience:

  • Customizable Dashboards: Provide tailored visual interfaces for different roles (management, engineers, operators).
  • Multi-Platform Support: Monitor factory operations in real-time on desktops, tablets, and mobile devices.
  • Smart Alert System: Notify responsible personnel via APP notifications or emails in case of production anomalies, equipment failures, or inventory shortages.
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Integration Capabilities with ERP / SCADA / PLM

MES seamlessly connects with enterprise information systems to ensure data consistency and efficient operations:

  • ERP Integration: Interfaces with SAP, Oracle, and other ERP systems to synchronize orders and production plans.
  • SCADA Connectivity: Collects real-time machine data, monitors equipment performance, and enhances production stability.
  • PLM Support: Directly accesses BOM (Bill of Materials) and process documentation to ensure production consistency.

Technical Support & Implementation Services

When implementing an MES system, businesses are most concerned about deployment and maintenance costs. We offer comprehensive technical support and services:

  • Professional Implementation Services: Covers the full process from requirement analysis, system planning, and customization to deployment and testing.
  • Training Programs: Provides extensive training for operators, IT maintenance personnel, and management to ensure smooth system adoption.
  • Technical Support: Offers online and on-site assistance to ensure the stable operation of the MES system.

MES is a key technology for enterprises transitioning to smart manufacturing. Through real-time monitoring, production optimization, quality management, and data analysis, it enhances overall manufacturing efficiency. Our MES solution not only improves production efficiency but also reduces operational costs, ensures product quality, and enables seamless data integration, empowering businesses to achieve smart factory transformation.

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