Article Type: FAQ Audience: All Users Module: FAQ
Manufacturing Execution Systems (MES) represent one of the most misunderstood technologies in industrial automation. While many believe they can purchase MES "off the shelf" with minimal configuration, the reality is starkly different. This article addresses common misconceptions about MES implementation and clarifies why every organization ultimately builds their MES system, whether they realize it or not.
Important: The opinions and views within this video are from a well-known industry expert, Walker Reynolds.
🎥 Video walkthrough: MES Build vs Buy Reality Check — Watch on YouTube
The Fundamental Truth About MES
You Will Build, Not Buy
Critical Point: Every manufacturer will build their MES system. This isn't a choice — it's an inevitable reality. The only question is whether you'll:
- Build from day one with a proper platform
- Waste money on off-the-shelf solutions first, then build later
- Purchase tools and platforms, then extend them (which is still building)
Why MES Can't Be Bought Off-the-Shelf
Unlike SCADA systems, which have standardized functions across all implementations, MES represents an abstraction for business-specific functions that are core to what each manufacturer does. Manufacturing execution is literally where manufacturing takes place — making it impossible to standardize.
Understanding the MES Complexity Pyramid
The Automation Workforce Distribution
Industry Statistics:
- 60% of professionals work at Level 1 (PLC/HMI controls)
- A smaller percentage work at Level 2 (SCADA)
- A microscopic number work at Level 3 (MES)
Why So Few Work in MES
Only 5–10% of manufacturers have digital manufacturing execution systems, despite all having the same fundamental problems. The reason: MES is extraordinarily difficult. It's so complex that you cannot build an effective off-the-shelf solution.
The Core Four: Essential MES Functions
Every MES implementation includes these fundamental capabilities, regardless of industry or business model:
1. Work Order Management
Always Present in Every Implementation
- Converts planned manufacturing (from ERP) into executable work orders
- Creates abstraction for all work performed on production lines
- Bridges planning systems with execution reality
- May use actual ERP work orders or abstract shift/hourly work orders
Why It's Core: You always need some work order structure to track events against, even in proof-of-concept implementations.
2. Scheduling Management
Universal Requirement
- Manages production sequencing and timing
- May consume schedules from ERP or create internal schedules
- Includes everything from shift-level to detailed production scheduling
- Maps planned work to actual process control events
Why It's Core: Even with minimal scheduling (hourly or shift-based), you're always doing some form of schedule management.
3. Overall Equipment Effectiveness (OEE)
The Most Critical Metric
- Requires only 5 data points: state, infeed count, outfeed count, waste count, standard rate
- Can calculate with just 2 of the 3 counts (the third can be derived)
- Always the first analytical function implemented
- Comprises availability, performance, and quality metrics
Why It's Core:
- Literally the first data points connected in any MES implementation
- Enables comparison of unlike assets using standardized metrics
- Essential for identifying where to invest time and resources
Business Value: OEE provides the abstraction needed to compare completely different processes using one standardized number, enabling data-driven investment decisions.
4. Downtime Tracking
Subset of OEE but Called Out Separately
- Categorizes and reports on equipment downtime events
- Often the only function implemented in initial phases
- Routes state events for categorization and analysis
- Foundation for continuous improvement initiatives
Why It's Core: Frequently the sole focus of proof-of-concept implementations, demonstrating its fundamental importance.
Extended MES Capabilities: Beyond the Core Four
Quality Management Functions
Not Core Functions:
- Recipe Management: Important for batch processes but not universal
- Digital Quality Inspection Plans (DQIP): Valuable but not implemented for years in many systems
- Statistical Process Control (SPC): Increasingly handled at the edge level
- Track and Trace: Important but highly variable between organizations
Why Track and Trace Isn't Core
Evidence Against Core Status:
- Most organizations operate with paper-based traceability for years
- When quality issues arise, they spend weeks manually tracking genealogy
- Different definitions across organizations (some want raw materials only, others want complete process history)
- Rarely implemented in proof-of-concept phases
- Typically addressed 6–12 months after initial MES deployment
Other Extended Functions
- Digital work instructions
- Inventory management integration
- Materials handling and line supply
- ERP integration
- Finite scheduling
- Document management
Common Misconceptions Debunked
Myth: Quality Is the Primary Driver for MES
Reality: The top reasons manufacturers implement MES are:
- Real-time insight into current state — need immediate visibility into operations
- Performance comparison across assets — use OEE to compare unlike processes
- Quality management — important but typically ranks in the top 5, not #1
Myth: Off-the-Shelf Solutions Work with Configuration
Reality: Software developers must make assumptions about business operations to create data models that work for MES functions. These assumptions never align perfectly with actual business needs.
Myth: Integration Is a Core Function
Reality: While important, ERP integration typically occurs 6–12 months after initial MES implementation. It's extended functionality, not core.
How Fuuz Solves the Build vs. Buy Dilemma
Every MES is unique, and the Fuuz platform provides the foundation for building exactly what each business needs:
Core Four Foundation:
- Work Order Management: Flexible work order abstraction that adapts to any business process
- Scheduling Integration: Seamless connection with existing planning systems
- OEE Engine: Real-time calculation and analysis of equipment effectiveness
- Downtime Analytics: Comprehensive categorization and reporting
Extensible Architecture:
- Start with Core Four implementation
- Add extended capabilities as business needs evolve
- Integrate with any existing system or process
- Customize without platform limitations
The Fuuz Advantage
No Assumptions About Your Business:
- Platform adapts to your unique processes
- No forced standardization that eliminates competitive advantage
- Flexible data models that accommodate any manufacturing workflow
Built for Extension:
- Add track and trace when ready
- Integrate quality management systems
- Connect with existing ERP and planning systems
- Scale functionality as business grows
Industrial-Grade Reliability:
- Connect, collect, and store industrial data reliably
- Real-time processing for time-critical operations
- Proven in diverse manufacturing environments
The Learning Process: Why Building MES Teaches You About Your Business
Discovering Your Manufacturing Workflow
Building MES forces organizations to clearly define:
- How they sell products
- How they plan manufacturing
- How they execute manufacturing
- How they monitor and control processes
- How they manage inventory and shipping
At a high level, manufacturing isn't complicated — every manufacturer follows the same basic pattern. The complexity lies in the unique details of how each organization executes these functions.
Business Process Documentation
The MES building process reveals:
- Hidden inefficiencies in current processes
- Opportunities for improvement and optimization
- Critical data points for decision-making
- Integration points between different business functions
Why Fuuz Is the Right Choice for Your MES Journey
Honest Assessment
Fuuz acknowledges what others won't: you're going to build your MES regardless. The platform provides the right foundation to do it efficiently and effectively.
Proven Methodology
- Start with Core Four implementation
- Use a proven industrial IoT platform
- Extend capabilities based on actual business needs
- Learn about your business through the building process
Future-Proof Architecture
- Platform grows with your business
- No limitations on customization or extension
- Integrate with any existing or future systems
- Adapt to changing business requirements
Conclusion
The debate about building vs. buying MES isn't really a debate — it's a fundamental misunderstanding of what MES represents. Every organization builds their MES because every organization's manufacturing execution requirements are unique to their business.
The real choice is whether to start with the right foundation or waste time and money on solutions that can't accommodate your actual needs. Fuuz provides that foundation: a platform that acknowledges the reality of MES complexity while providing the tools to build exactly what your business requires.
Remember: MES is not MES is not MES. Every implementation is unique because every business is unique. The question isn't whether you'll build — it's whether you'll start with the right foundation.
See Also