Table of Contents
- 1 60 + MES Software Survey facts – Manufacturing Execution System Software Capabilities
- 1.1 MES system and Big Data Analytics – Popular uses for MES Software and iIoT
- 1.2 MES Software – What is the data being used for from your MES?
- 1.3 MES Solutions – Zero Defects
60 + MES Software Survey facts – Manufacturing Execution System Software Capabilities
- Sixty-six percent (66%) of the manufacturers responding reported a reduction in manufacturing time of 45% or greater.
- Sixty-six percent (66%) of the manufacturers responding reported a reduction in entry time of 75% or better.
- Fifty-seven percent (57%) of the manufacturers responding reported a reduction in WIP of 25% or better.
- Sixty-three percent (63%) of the manufacturers responding reported a reduction in paperwork between shifts of 50% or better.
- Sixty-three percent (63%) of the manufacturers responding reported reduction in lead time of 35% or better.
MESA.ORG: All of these figures are merely some of the direct benefits of MES, and do not include any indirect.
With this in mind MESA International reports their most indelible fact, MES Software ROI “Return On Investment/Payback Period (14 Months Average).” This is truly impressive because for the initial investment of an MES software system can be enormous depending on complexity and size.Source: Source: R. Elliot – Manufacturing Execution system (MES) An Examination of Implementation Strategy
- Output rose by 15% and First pass yield rose by a median of 14% from MES Software
- Many companies had better improvement in first pass yield with a third quarter of over 50%.
- Net profit margin increased by 5%
- Revenue per employee increased by 7%
- Manufacturing cost per unit improved by 10%
Therefore, It is interesting to consider a correlation between this and the very high numbers we saw for participation in a variety of continuous improvement programs below.
MES software – MANUFACTURING METRICS – Other Improvements
- Improvement in manufacturing cycle time – 16% when using MES SoftWare
- NPI (New Product Introduction) Improve – 20%
- Increase of SKU/Products – 15%
- Planned vs. emergency Maintenance – 20%
- Annual Inventory turns Improvement – 27%
- Production Schedule Attainment Improvement – 10%
- Improvement in customer rejects/returns – 5%
- Improvement in reported Environmental incidences – 35%
- Health and Safety Improvement incidences – 37%
MES system and Big Data Analytics – Popular uses for MES Software and iIoT
Most Popular Uses for: iIot and Manufacturing Execution System – MES Software
- MES Software for: Continuing improvement manufacturing process – 43%
- MES Software for: Operational Excellence Programs – 27%
- MES Software for: Better forecasts of production across multiple plants – 27%
- MES Software for: Better forecasts of a production plant – 27%
- MES Software for: Additionally, Continuous asset performance (APM) improvement across multiple plants – 23%
- MES Software for: Real-time alerts based on analyzing manufacturing data – 22%
MES Software – What is the data being used for from your MES?
Considering, when thinking outside the box when it comes to MES Software, data usage is probably not high on the agenda of those focused on production improvement and better process management. Having looked at usage, we were interested in the “how” of Big Data Analytics. We asked, “From where does your company get or plan to get its analytics experience?” To our astonishment, 40% said that they have a strong analytics team that will not require much expansion. This goes directly in the face of perceived wisdom on the
subject; most pundits claim that the lack of data science skills will hold back some companies in their pursuit of iIoT and Big Data Analytics in manufacturing. MES Software can assist with this.
Moreover, when considering the results of the above question in the context of this one, it starts to come into focus that Big Data claims in manufacturing companies might be slightly ahead of the reality. Manufacturers already have advanced analytics in Enterprise Manufacturing Intelligence (EMI) and Business Intelligence (BI), for which they probably have sufficient skills.
Interestingly, when it comes to Big Data, with unstructured information like video, climate, and image information, and when companies want to delve much deeper into their manufacturing and business data across supply chains, we suspect they will need new skills about which they know little today. Indeed, these new systems will hopefully answer questions about the business that we do not yet even know to ask. By looking at the type of data being used in analytics systems we can start to understand some of these issues. Most Big Data algorithms such as machine learning and sentiment analysis are still little used. This shows us that here is probably a gap of skills not necessarily recognized yet. Engineers and data scientists have different views of what predictive analytics are; one is very model- and simulation-centric, while the other is data- and correlation-centric. Like the historical lack of trust between plant and IT technicians, Today there is distrust between the groups. A key to success in Big Data Analytics is to bring them together from a mathematical as well as cultural perspective. MES software can help achieve this.
When asked: Which ( mes ) manufacturing software does your company currently use?
Furthermore, Fifty-nine percent(59%) DID NOT know which MES Software (Manufacturing Executions Software) they used.
- Continuing Improvement – manufacturing process – 43%
- Better forecasts of a production plant – 27%
- Better forecasts of production across multiple plants – 27%
- Operational Excellence programs – 27%
- Continuous asset performance (APM) improvement across multiple plants – 23%
- Real-time alerts based on analyzing manufacturing data – 20%
- Improved customer service and support – 17%
- Understand customer requirements for new products – 17%
- Finding key plant performance parameters through correlation – 17%
- Better forecasts of sales – 13%
- Reduced recalls – 13%
- Correlate manufacturing and business performance information together – 13%
- Mine combinations of manufacturing and other enterprise data – 13%
- Alert management across multiple plants – 13%
- I don’t think we use Enterprise Big Data – 13%
- Improve relationships with suppliers – 10%
- Correlate performance across multiple plants – 10%
- I don’t think we use Plant Big Data – 10%
- Perform predictive modeling of manufacturing data – 7%
- Tracing products outside the enterprise – 7%
- Don’t know – 7%
- Delivering software upgrades directly to sold devices – 0%
- Other ways – 0%
MES Solutions – Zero Defects
You now are able to integrate your legacy systems and bring in an MES solution to enhance your facility to improve Original Equipment Efficiency – OEE, quality and profits! Our proven integration methodology have been executed thousands of times successfully. Capturing your manufacturing data is a key component to moving your facility towards a success Industry 4.0 integrated platform. With relative ease, you can extract your data, harness the information and allow your leaders and team to make very informed decisions.
Here’s to ZERO customer defects! Contact us with any questions you may have about Ujigami & MES
LNS Research Manufacturing Metrics