Digital Operations
Manufacturing Execution Systems – MES Consulting
Competitive Advantage Through MES Integration
How do successful manufacturing companies manage to produce efficiently despite a shortage of skilled workers, rising costs, and increasing customer demands? The answer lies in transparent and optimally managed processes. The selection, implementation, and integration of a Manufacturing Execution System (MES) lays the foundation for greater transparency, higher productivity, and secure manufacturing processes. Through the intelligent networking of production data, machines, and systems, potential is unlocked, processes are optimized, and resources are utilized efficiently. With professional MES consulting, you can therefore sustainably increase your competitiveness and make your production ready for the future.
MES Selection
We’ll guide you through the maze of vendors—for a seamless and tailored MES integration
Selecting the right manufacturing execution system is a highly complex decision. Consequently, the biggest challenges stem from the fact that the transition affects the entire order processing workflow and therefore requires a comprehensive solution. Structures in the system landscape and process execution that have evolved over the years are often highly customized, sometimes opaque, and frequently unknown. As a result, the compatibility of actual processes often cannot be aligned with what vendors offer. A well-founded approach within the framework of MES consulting helps to manage this complexity by analyzing existing processes, structuring requirements, and identifying suitable solutions. Many companies therefore postpone the selection of an MES for as long as possible, which in turn leads to increased time pressure. Additionally, the multitude of vendors complicates the selection process, as companies often fail to recognize the differences between the solutions.
Our production and process specialists will guide you through the entire selection process for MES integration and beyond, if needed. To ensure a structured approach, we work with you to identify the critical business processes and key users, which we then use to create a requirements specification and a long list of potential solutions. Furthermore, drawing on our extensive experience in process consulting, we map the current production processes and work with key users to define new target processes. These serve as the basis for selecting potential vendors (shortlist).
This is followed by workshops in which the vendors present their solutions to you. To this end, we work with you to develop an evaluation framework. We then use all the information gathered to formulate a recommendation for action and draft a roadmap for the MES implementation. We also use our expertise to assist with the final contract draft to ensure that the provider meets your requirements.
Our Service Packages:
- Develop a long list and a short list
- Create a requirements specification based on process development
- Prepare tender documents and specifications for system and vendor selection
- Conduct beauty contests with potential vendors
- Evaluate potential solutions and develop recommendations for action
- Develop a roadmap for MES implementation
Benefits for you:
- System selection tailored to your processes and requirements
- Personalized Roadmap for the System’s Implementation
- Relieve the burden on your departments through professional management of the selection process
- High confidence in decision-making thanks to a structured and objective selection process from the perspective of a process consultant.
Philipp Kappus
Senior Production Manager
Feel free to contact me!
Are you planning an MES project and looking for an experienced partner? Then please send me a message. I will get back to you as soon as possible.
MES Implementation
The Right Building Blocks for Successful MES Integration
Once the selection process has been completed and a decision has been made regarding the system provider, the next step is to implement the selected system in your company and successfully replace the legacy system. This involves configuring the Manufacturing Execution System to meet your requirements, potentially developing custom modules, or creating interfaces with existing systems. A structured MES integration ensures that these transitions proceed smoothly and that ongoing operations are not disrupted. Furthermore, MES integration usually also requires adjustments to work organization and the design of new, lean processes. Early-stage MES consulting ensures that all relevant requirements are identified in a timely manner and taken into account in project planning. Because only when MES integration is approached holistically—both technically and organizationally—can the system’s full potential be realized.
To ensure your employees can work successfully in the new system once it goes live, it is important to train them on the newly established structures and system functions. The challenge lies in efficiently managing the complex MES project while simultaneously engaging and empowering your staff to embrace the upcoming changes and working with them to build a future-ready organization with lean yet effective workflows. Our comprehensive MES consulting services support your company through every phase of the implementation process—using a methodical, process-oriented, and practical approach.
We are your partner for the successful and seamless implementation of the Manufacturing Execution System in your company—from project planning and management to the development of lean target processes using the new system, to training specialists as part of a change management process, and supporting system configuration and business integration from a process perspective.
Our Service Packages:
- Project and stakeholder management to ensure compliance with defined project objectives
- Develop target processes to design an optimal workflow using the new MES
- Identify the need for changes (e.g., organizational adjustments)
- Managing and Supporting Change and Transformation Processes
- Providing Process-Based Support for Business Integration Tests
- Compare the results of implementation with the defined requirements
Benefits for you:
- A smooth and targeted implementation of your MES system
- Streamlined and future-proof processes for efficient production
- Reliable implementation of the defined requirements in terms of time, budget, and quality
- Involvement of all stakeholders, key users, and process owners in the MES project
Organizational Development
Unlock the Potential of Your Employees
Is there a lot of untapped potential within your organization? Is there a lack of initiative for improvement, or has development come to a standstill? To build a successful and sustainable business, you need a clear vision, mission, and strategy. Based on these, it is essential to create a foundation for stability, progress, and development. This also involves consistently and evenly advancing and balancing the development of corporate structures, competencies, and culture.
An MES integration not only leads to structural changes but also impacts employee skills and corporate culture. While this process presents a challenge, it also offers an opportunity to drive change within your organization. Work with us as part of our MES consulting services to lay the foundation for building a dynamic organization with intrinsically motivated employees.
Our Service Packages:
- Define the vision and mission and develop a corporate strategy
- Developing Goals and Key Performance Indicators
- Develop structural elements with your teams
- Developing a Goal- and Solution-Oriented Leadership Culture
- Continuously support and empower stakeholders throughout change and development processes
- Implementing Agile Work and Thinking Styles in the Organization
Benefits for you:
- A clear strategic direction for a sustainable organization
- Greater motivation and personal responsibility among your employees
- A greater willingness to embrace change and accept new ways of working
- Promoting goal- and solution-oriented employees
Process Consulting
Lean, value-driven end-to-end processes with MES consulting
Are your business processes undocumented or only partially documented? Or is the existing documentation outdated and no longer current? Often, processes within a company are created only within individual departments, but are neither designed with a focus on value from the customer’s perspective nor across departments. Such processes are not suitable as a basis for selecting and implementing a Manufacturing Execution System. MES integration offers significant potential for optimization in this regard. End-to-end processes are developed in collaboration with key users, focusing on customer value (e.g., higher delivery reliability, on-time delivery, or faster response times). When implementing an MES, it is therefore crucial to choose a provider that aligns with your company’s target processes and supports sustainable process optimization.
Drawing on our many years of experience, we help you analyze your current processes, identify opportunities for optimization, and create value-driven end-to-end target processes. We apply state-of-the-art methods for process optimization. Based on this, we define use cases for vendor selection and identify standardized and customized solutions. During the rollout of the new system, we refine the end-to-end processes and adapt them to specific requirements. This ensures that your employees can work with efficient, system-supported workflows at the time of implementation—and that they are actively involved in developing these new processes.
Our Service Packages:
- Record and document current processes with key users
- Develop target processes collaboratively with key users in a pragmatic manner from the outset
- Define use cases for the beauty contest and vendor selection
- Further develop end-to-end target processes based on the functions in the new system
Benefits for you:
- Transparency regarding opportunities for optimization throughout the process chain
- Streamlined and customer-focused end-to-end processes
- Selection of vendors based on target process structures
- Seamless integration between MES and target processes
System Environment and Configuration
Transparent Assessment: Identify Risks and Vulnerabilities, Define the Target State
The rapid development of new IT solutions presents challenges for many departments. The swift implementation of new solutions—particularly MES integration—is crucial to business success, yet a holistic approach often falls by the wayside.
The result: The IT landscape of many companies consists of a collection of siloed solutions. These make maintenance time-consuming and cause potential benefits at the interfaces to be lost. This leads to two key problems: New technologies are difficult to apply to distributed systems, especially when individual systems or versions are being phased out. Furthermore, there is often a lack of experts for older systems. Consequently, conducting a risk assessment of the IT landscape is virtually impossible.
To ensure the successful integration and implementation of your MES, we conduct a thorough review of your entire system landscape as part of our MES consulting services. Drawing on our extensive operational and process expertise, we document and analyze the key systems and workflows across all departments. This creates a digital map of your system landscape that takes into account both existing and missing interfaces.
In joint workshops with the various departments, we develop a digital roadmap for your system landscape. In doing so, we always keep the latest state-of-the-art solutions in mind. Together with you, we then decide which systems and processes will continue to operate independently and which should be covered by the MES. We place particular emphasis on the potential MES integration of interfaces with APS (Advanced Planning and Scheduling), PPS (Production Planning System), BDE (Operational Data Collection), and MDE (Machine Data Collection). Throughout the entire implementation process, we act as a liaison between the implementation provider and the business department to ensure a customized configuration that meets your requirements.
Our Service Packages:
- Provide transparency regarding the existing system landscape
- Document the current state of the systems, interfaces, and data flows
- Identify relevant systems and dependencies
- Integrate MES into the existing system landscape
- Develop a vision for a future-proof IT infrastructure
Benefits for you:
- Overview of Systems, Interfaces, and Dependencies
- Identifying risks and opportunities for optimization in your IT environment
- Future-proof system architecture for continued growth and digitalization
Change Management
Mastering MES Transformation Through Systematic Change Management
The implementation of a new Manufacturing Execution System brings significant changes and challenges for all employees. Old habits must be set aside as new workflows and structures take shape. Ideally, these changes should be driven by the employees themselves to maintain their motivation both during and after the implementation. Structured and customized change management is essential for this. It lays the foundation for successfully navigating the various phases of the MES project by implementing targeted measures for communication, training, and empowerment.
We would be happy to work with you to develop a change management strategy that includes specific measures tailored to the individual needs of your employees at every stage of the project. This will ensure that your employees’ performance and motivation remain high both during and after the MES integration, and that they play an active role in shaping the change process.
Our Service Packages:
- Develop a change management plan
- Develop specific measures to support change
- Develop a communication strategy and communication initiatives
- Develop training and competency development plans that include appropriate measures
- Track all implemented measures and evaluate their effectiveness
Benefits for you:
- Efficient implementation of the new system in your organization
- Transparent and target-audience-specific communication during the transformation
- Qualified professionals with the necessary expertise in new processes and systems
- High motivation and active participation of your employees in the change process
PMO
Leading the MES Project to Success with Structured Project Management
Implementing an MES is a complex and challenging undertaking. It involves a wide range of stakeholders before the system is rolled out across the entire organization. Therefore, effective project management is essential for engaging all stakeholders and meeting the diverse requirements. Clearly defined project goals and scope, as well as a functional collaboration model involving all stakeholders, are essential for successfully implementing the MES project. It is also important to communicate progress, challenges, and risks transparently.
We are happy to assist you with this and bring our many years of diverse experience in project management to bear to ensure the success of your MES transformation. We set up the project in a structured manner, define the project scope with clearly defined goals and milestones, and establish transparent structures for collaboration. We continuously monitor the project’s progress, assess risks, and implement corrective measures. We ensure that your MES project is provided with the appropriate project management framework so that you can achieve your goals and project scope with the planned resources, within the defined quality and timeframe.
Our Service Packages:
- Define Project Goals and Milestones
- Develop a detailed phase and milestone plan
- Define tasks, roles, and responsibilities
- Develop a collaboration model for all project participants
- Monitor project progress and manage risks associated with schedule deviations (project controlling)
- Implement an agile project management framework as needed
Benefits for you:
- Transparency regarding project progress, dependencies, and risks
- Structured Management of a Complex MES Project
- Efficient and Effective Collaboration Within the Project Team
- Greater reliability in meeting deadlines, staying within budget, and achieving goals through experienced project management
FAQ
How do you choose the right MES for a manufacturing company?
The selection of a Manufacturing Execution System should not be based solely on its range of functions or a vendor presentation. The key factor is how well the MES fits with the company’s existing—and, in particular, future—production processes, requirements, and system landscape. To achieve this, the relevant current processes are first analyzed, and optimized target processes are developed in collaboration with key users. Based on this, requirements, use cases, and evaluation criteria can be defined, suitable vendors identified, and compared in structured workshops. This creates a solid foundation for making a decision regarding the MES selection.
What criteria are key when selecting an MES?
The most important criteria include functional coverage of the relevant production processes, the ability to integrate into the existing system landscape, the mapping of defined target processes, as well as the scalability and future-proofing of the solution. Interfaces to systems such as ERP, APS, PPS, BDE, and MDE should also be considered early on. A customized list of requirements and an appropriate evaluation framework provide the basis for objectively comparing different MES solutions. Rothbaum Consulting can specifically involve the relevant departments in the development of these criteria.
What should be considered when integrating an MES into an existing system landscape?
When integrating an MES, existing systems, interfaces, data flows, and responsibilities must be considered holistically. Connections to ERP, APS, PPS, BDE, and MDE, for example, are particularly relevant. An analysis of the existing system landscape identifies dependencies and forms the basis for a consistent target vision. It is also important to clarify early on which functions will be handled by the MES in the future and which systems or processes will remain in place. Rothbaum Consulting supports companies in this holistic approach and in developing a suitable integration strategy.
How does Rothbaum Consulting help companies select and implement an MES?
Rothbaum Consulting supports companies from the analysis of existing production processes through the selection of an MES to its implementation and integration. This includes, among other things, the development of requirements catalogs, long and short lists, the preparation and facilitation of vendor workshops, the evaluation of solutions, the development of target processes, and the creation of an implementation roadmap. During implementation, Rothbaum Consulting also provides support in project management, change management, business integration, and coordination between business units and implementation partners.
More Information
Transparency and Control in Modern Manufacturing
In an increasingly dynamic industrial landscape, manufacturing companies face the challenge of designing complex production processes in a way that is transparent and highly efficient. A Manufacturing Execution System serves as the central link between strategic corporate planning and operational processes on the shop floor.
To realize the full potential of this technology, its implementation or modernization requires targeted MES consulting. A structured analysis of existing manufacturing structures identifies weaknesses and precisely defines requirements. The goal is to make real-time production data usable in order to minimize downtime, sustainably increase equipment efficiency, and create a consistent data foundation for informed decisions.
Vendor-neutral selection of the right MES system
The market for software solutions in the field of manufacturing execution is diverse and characterized by a wide range of different providers. Vendor-neutral MES consulting offers companies the decisive advantage of selecting a solution that is optimally suited to their specific production processes and existing IT infrastructure.
As part of the selection process, functional requirements are defined, specifications are drawn up, and proposals are evaluated objectively. This helps prevent poor investment decisions and ensures seamless integration with existing systems such as ERP or quality management. A customized requirements profile ensures that the selected system remains flexibly scalable and is capable of meeting future requirements.
Sustainable Process Optimization and Successful Implementation
Simply selecting the right software does not guarantee long-term project success. It is only through systematic support during the implementation phase that MES consulting achieves its full potential. Experts provide assistance with modeling production processes, integrating the system into day-to-day operations, and training managers and employees.
Continuous change management helps foster long-term acceptance of the new technology within the company. After implementation, measurable key performance indicators enable transparent performance monitoring. This ensures the long-term success of digital transformation in manufacturing, while reducing process costs and significantly increasing productivity.
