Digital Operations
Manufacturing Execution Systems – MES Consulting
Competitive advantage through MES integration
Today more than ever, manufacturing companies in all sectors are feeling the burden of fulfilling customer orders in ever shorter timeframes and to the highest quality standards. Production is increasingly being defined as a central process in the entire value chain and therefore as an important competitive advantage. This requires fast, flexible and efficient manufacturing and assembly processes. At the same time, companies are under pressure due to labor shortages. In this context, not only the automation of machines and systems plays an important role, but also the continuous recording, control and optimization of production processes in order to avoid personnel bottlenecks and increase process reliability. MES consulting and MES integration provide you with support in this matter.
Create secure processes and avoid staff shortages with the right MES implementation
A suitable Manufacturing Execution System (MES) can integrate all relevant areas of production and assembly, from production planning, production control, quality assurance and traceability through to machine and plant utilization. Accordingly, MES integration provides a complete overview of these processes and organizes them via corresponding (standard) interfaces.
A modern MES works closely with other systems and technologies to efficiently control and optimize the entire production process: By connecting to or integrating with APS (advanced planning and scheduling), BDE (production data acquisition) and MDE (machine data acquisition), a manufacturing execution system ensures precise planning, real-time transparency and optimal resource utilization. In addition, the integration with ERP and SCM systems as well as modern technologies, e.g. IoT and robotics, increases efficiency and responsiveness. A powerful MES thus creates the basis for flexible, transparent and competitive production. As a holistic MES consultancy, Rothbaum is happy to support you in the following areas:
MES selection
As experienced MES consultants, we guide you through the jungle of providers
Choosing the right manufacturing execution system is a very complex decision. As a result, the biggest challenge is that the changeover affects the entire order handling process and therefore requires a comprehensive solution. Structures in the system landscape and process execution that have evolved over the years are often very individual, partly non-transparent and frequently unknown. As a result, it is often not possible to compare the compatibility of the processes in place with the providers’ offerings. Many companies therefore postpone the selection of an MES for as long as possible, which in turn results in increased time pressure. In addition, the large number of providers makes the selection process more difficult, as the differences between the solutions are often not recognized by the companies.
Our production and process specialists will guide you through the entire selection process as part of MES consulting and beyond if required. To enable a structured approach, we jointly define the decisive company processes and key users, on the basis of which we create a catalog of requirements and a long list of possible solutions. Furthermore, we use our extensive experience in process consulting to record the actual processes in production and define new target processes with the key users. These serve as the basis for the selection of possible providers (short list).
This is followed by workshops in which the providers present their solutions to you. We develop an evaluation scheme together with you. We then draw up a recommendation for action for you based on all the information gathered and design a roadmap for the MES introduction. We also use our expertise to support the final draft contract to ensure that your requirements are met by the provider.
Our service packages:
- Develop longlist and shortlist
- Create requirements catalog after process development
- Create tender documents and specifications for system and supplier selection
- Develop and carry out beauty contests with potential providers
- Develop a recommendation for action
- Create a roadmap for MES introduction
Your benefit:
- You receive a tailor-made system for your core processes in operations and beyond.
- Our MES consulting service provides you with a personalized roadmap for the introduction of the system.
- You benefit from holistic support during the selection process from the perspective of a process consultant.
Philipp Kappus
Production Manager
Talk to us!
Would you like to introduce an MES or do you need support with the necessary steps? Then please send me a message. I will get back to you as soon as possible.
MES introduction
Successful MES implementation with the right building blocks
Once the selection process has been carried out and the decision has been made in favor of a system provider, the next task is to introduce the selected system in your company and successfully replace the old system. This involves configuring the manufacturing execution system to your requirements, possibly developing sub-scopes or creating interfaces to existing systems. In addition, the MES integration usually also requires an adjustment of the work organization and the design of new, lean processes.
To ensure that your employees can work successfully in the new system when it goes live, it is important to familiarize them with the newly created structures and system functions. The challenge is to manage the complexity of the MES project efficiently, to empower and support your specialists in the upcoming change and to work with you to build a future-proof organization with lean but effective workflows.
We are your partner for the successful and smooth implementation of the Manufacturing Execution System in your company – from the planning and management of the project to the development of lean target processes with the new system, the training of specialists as part of a change management process, through to support for the system configuration and business integration from a process perspective.
Our service packages:
- Project and stakeholder management in order to meet defined project goals (e.g. time frame, costs, requirements)
- Develop target processes to design an optimal workflow with the new system
- Derive the need for changes (e.g. organizational adjustments)
- Managing and supporting change and transformation processes
- Business integration tests support processes
- Compare the success of the implementation with the defined requirements
Your benefit:
- You introduce the Manufacturing Execution System efficiently.
- You establish lean and optimized processes.
- You implement the defined requirements.
- You involve all stakeholders, key users and process owners in the MES project.
Organizational development
Exploit the potential of your employees
Is there a lot of untapped potential in your organization? Is there a lack of initiative for improvement or is further development stagnating? To build a successful and sustainable company, you need a clear vision, mission and strategy. Based on this, you need to create a breeding ground for stability, progress and development. This also means that you must constantly promote and balance the development of corporate structures, skills and culture.
MES integration not only leads to structural changes, but also has an impact on the skills of employees and the corporate culture. This process presents a challenge, but at the same time offers the opportunity to initiate change in your organization. Work with us to lay the foundations for building a vibrant organization with intrinsically motivated employees as part of MES consulting.
Our service packages:
- Define vision and mission, derive corporate strategy
- Developing targets and key performance indicator systems
- Developing structural elements with your teams
- Develop a goal- and solution-oriented management culture
- Continuously support and empower stakeholders in change and development processes
- Implement agile ways of working and thinking in the organization
Your benefit:
- With our support, you define your vision, mission and corporate strategy.
- You motivate your employees intrinsically.
- They promote goal- and solution-oriented managers and employees.
Process consulting
Lean, value-oriented end-to-end processes as part of the MES introduction
Are your business processes not or only incompletely documented? Or is the existing documentation outdated and no longer up to date? Often, processes in a company are only created within individual departments, but are neither value-oriented from a customer perspective nor cross-departmental. Such processes are not suitable as a basis for the selection and introduction of a Manufacturing Execution System. MES integration offers great potential for optimization. End-to-end processes are developed with the key users, which are oriented towards customer value (e.g. higher delivery reliability or adherence to delivery dates or faster responsiveness). When introducing an MES, it is therefore crucial to choose a provider that matches your company’s target processes and supports sustainable process optimization.
With our many years of experience, we help you to analyze your current processes, identify optimization potential and create value-oriented end-to-end target processes. We apply state-of-the-art methods for process optimization. Based on this, we define use cases for the selection of providers and identify standardized and individual solutions. During the introduction of the new system, we refine the end-to-end processes and adapt them to the specific requirements. In this way, we ensure that your employees can work with efficient, system-supported workflows at the time of implementation – and that they themselves are involved in the development of these new processes.
Our service packages:
- Record and document actual processes with the key users
- Initial and pragmatic development of target processes together with key users
- Define use cases for the beauty contest and provider selection
- Further develop end-to-end target processes based on the functions in the new system
Your benefit:
- You identify optimization potential along the process chain.
- You develop sustainable and value-oriented target processes.
- You select your provider on the basis of target process structures.
- They ensure harmonious interaction between MES and target processes.
System landscape and configuration
Transparent inventory: identify risks and weak points, define target image
The rapid development of new IT solutions poses challenges for many specialist departments. Rapid implementation of new solutions, especially MES integration, is crucial for commercial success, but a holistic approach usually falls by the wayside.
As a result, the IT landscape of many companies is a collection of isolated solutions. This makes maintenance time-consuming and causes potential to be lost in the interfaces. This results in two central problems: New technologies are difficult to apply to the distributed systems, especially when individual systems or versions are phased out. Knowledge carriers for older systems are then often missing. A risk assessment of the IT landscape is therefore virtually impossible.
To ensure the successful implementation and integration of a manufacturing execution system, we examine your entire system landscape. With extensive operational and process experience, we document and examine the key systems and processes of all departments. This creates a digital picture of your system landscape that also takes existing and missing interfaces into account.
In joint workshops with the various departments, we develop a digital target image for your system landscape. In doing so, we always keep an eye on the latest state-of-the-art solutions. Together with you, we decide which systems and processes should be continued independently and which should be covered by the MES. We place particular focus on the possible MES integration of interfaces to APS (Advanced Planning and Scheduling), PPS (Production Planning System), BDE (Production Data Acquisition) and MDE (Machine Data Acquisition). During the entire implementation process, we act as a link between the implementation provider and the specialist department to ensure a customized configuration according to your requirements.
Our service packages:
- Create transparency
- Documenting the status quo
- Identify relevant systems
- MES integration into the existing system landscape
- Developing the ideal system landscape
Your benefit:
- You receive a transparent overview of the status of your current system landscape.
- You will be shown optimization potential.
- You minimize risks for your system landscape.
- You create a new system landscape for the optimized use of your data.
Change management
Mastering the MES transformation with systematic change management
The introduction of a new manufacturing execution system entails major changes and difficulties for all employees. Old habits have to be discarded while new work processes and structures are created. Ideally, these changes should be supported by the specialists themselves in order to maintain their motivation during and after the introduction. Structured and customized change management is essential for this. It creates the basis for mastering the various phases of the MES project by implementing targeted measures for communication, training and empowerment.
We will be happy to work with you to develop a change management strategy with specific measures that are individually tailored to the needs of your employees in each project phase. In this way, you can ensure that the performance and motivation of your specialists do not diminish during and after the MES integration and that they actively shape the change process.
Our service packages:
- Develop a change management concept
- Derive concrete measures to support change
- Develop a communication strategy
- Derive concrete communication measures
- Develop training and qualification concepts with corresponding measures
- Track all measures introduced and evaluate their effectiveness
Your benefit:
- You introduce the new system efficiently in your organization.
- You communicate the changes clearly and comprehensibly.
- Your employees have the necessary know-how to operate the new system efficiently.
- You keep the motivation of your employees high during the MES introduction.
PMO
Leading the MES project to success with structured project management
The MES introduction is a complex and demanding project. It involves a large number of stakeholders before the comprehensive rollout takes place. Effective project management is therefore of central importance in order to involve all stakeholders and meet the diverse requirements. Clearly defined project goals and content as well as a functioning collaboration model with all stakeholders are essential to successfully implement the MES project. It is also important to communicate progress, challenges and risks transparently.
We are happy to support you in this area and contribute our many years of diverse experience in project management to make your MES transformation a success. We set up the project in a structured manner, define the project scope with clearly described goals and milestones and create transparent structures for collaboration. We continuously measure the progress of the project, assess the risks and derive countermeasures. We ensure that your MES project has the right project management framework so that you achieve your goals and project scope with the planned resources in the defined quality and time.
Our service packages:
- Define project goals and milestones
- Develop a detailed phase and milestone plan
- Derive specific tasks and responsibilities
- Define collaboration model
- Monitor project progress and carry out risk assessment in the event of schedule deviations (project controlling)
- If required: Set up an agile project management framework for planning and controlling project tasks (e.g. based on Scrum, Safe, etc.)
Your benefit:
- You receive transparency on project progress and the risks in the project.
- You benefit from experienced project management.
- You will experience efficient and effective collaboration within the project team.
- They ensure the stringent implementation of the project.
