In today’s fast-paced manufacturing environment, achieving operational visibility is crucial for maintaining a competitive advantage. The integration of manufacturing operations management (MOM) and manufacturing execution systems (MES) offers a powerful synergy. It enhances operational visibility, drives efficiency and supports informed decision-making. This article explores the developments in MOM and MES, examining how their synergy can transform manufacturing operations.

Understanding MOM and MES

MOM encompasses a broad range of activities that support production, including quality management, logistics, materials management, time and labor, and maintenance.

MOM solutions provide a comprehensive approach to managing all aspects of manufacturing operations across an enterprise. This enables companies to optimize processes, ensure compliance and improve overall efficiency. Manufacturing execution systems, on the other hand, are focused on the shop-floor level. MES directs the activities of labor resources and materials, collects real-time production data and provides the necessary information to guide operators in their tasks. MES plays a critical role in monitoring, managing and optimizing day-to-day processes within a facility, providing visibility and control over shop-floor execution.

Why MES is Integral to MOM

While MOM and MES can operate independently, MES’s true potential exists when operating as part of a broader MOM framework.

This integration offers several benefits:

• Data Collection and Analysis in Real Time: MES provides real-time data collection and analysis, which is crucial for making informed decisions quickly. When integrated with MOM, this data can be leveraged across the entire organization. It allows you to optimize production planning, resource allocation and process improvements. MES collects data on production status, machine performance and operator activities. This information is fed into the broader MOM system, which then uses it to coordinate enterprise-wide activities.
• Standardization and Consistency: MES helps standardize production processes within a facility, ensuring consistency and efficiency. MOM extends this standardization across multiple facilities, enabling global enterprises to implement best practices and maintain consistent operations. The ISA95 standard, for instance, maps MES capabilities to the production dimension, emphasizing its role in achieving consistent operational practices.
• Quality Control Improvements: MES provides real-time monitoring and automated alerts to maintain product quality. MOM enhances this by integrating quality control into the overall manufacturing process, reducing defect rates and ensuring compliance with industry standards. MES captures detailed genealogy and traceability data, which MOM systems utilize to ensure compliance and quality across the enterprise.
• Resource Utilization: By integrating MES with MOM, companies can gain a comprehensive view of all operations, allowing for optimal resource utilization. This reduces costs and improves energy efficiency. MES optimizes day-to-day resource use, while MOM leverages this data to optimize broader logistics and supply-chain activities.
• Scalability and Flexibility: MOM systems are designed to be scalable, allowing companies to replicate successful processes across multiple plants. This scalability is enhanced by MES. It provides the detailed, real-time data needed to support continuous improvement and agile responses to changing market demands. MOM solutions, such as DELMIA’s Apriso, extend MES capabilities across global operations, providing a platform for managing complex manufacturing networks.
• Subset: It’s important to recognize that MES is essentially a subset of MOM. MES focuses on the production aspect, dealing with the granular, day-to-day execution on the shop floor. In contrast, MOM covers a broader spectrum, including not only production, but also quality management, logistics, maintenance and labor management. This hierarchical relationship allows MOM to utilize the detailed data from MES to enhance overall operational strategies. For example, while MES handles real-time production tracking and machine integration, MOM uses this data to manage and optimize the entire production life cycle, from raw-material procurement to final product delivery.

Developments in MOM and MES

Recent advancements in MOM and MES technologies have further enhanced their capabilities and integration potential. These developments include:

• IIoT Integration: IIoT technologies enable the collection of vast amounts of data from connected devices and machines. This data can be integrated into MOM and MES to provide deeper insights, predictive maintenance capabilities and enhanced process optimization.
• Cloud-Based Solutions: The shift toward cloud-based solutions for MOM and MES offers greater flexibility and scalability. Cloud platforms facilitate integration with other enterprise systems, support remote access and provide data security.
• Analytics and AI: The use of advanced analytics and artificial intelligence (AI) in MOM and MES allows for more sophisticated data analysis, predictive modeling and automated decision-making. These capabilities help manufacturers identify trends, optimize processes and reduce downtime.
• MES Architectures: As highlighted in Gartner’s research, the trend toward composable MES architectures allows manufacturers to tailor their systems to specific needs and integrate various functionalities more seamlessly. This flexibility supports a more agile and responsive manufacturing environment.

Overcoming Implementation Challenges

Despite the clear benefits, integrating MOM and MES can present challenges. Common obstacles include resistance to change, integration with existing systems and data-security concerns. Addressing these challenges requires a strategic approach.

• Stakeholder Engagement and Change Management: Engaging stakeholders early in the planning process and clearly communicating the benefits of MOM and MES integration can help overcome resistance to change. Implementing structured change-management programs is also essential for a smooth transition.
• Assessments for Compatibility and Gradual Integration: Conducting thorough evaluations of current systems and opting for a phased rollout can minimize disruptions and ensure a smoother integration process.
• Security Protocols and Regular Audits: Implementing advanced security measures and conducting regular audits can address data-security concerns and ensure compliance with industry regulations.

The integration of MOM and MES offers a transformative potential for manufacturing operations. By integrating these systems, companies can achieve enhanced operational visibility, improved efficiency and better decision-making capabilities. The developments in MOM and MES technologies further support this integration. It provides manufacturers with the tools they need to stay competitive in a rapidly evolving industry.

Investing in the integration of MOM and MES is a strategic move that can yield long-term benefits. These range from cost savings and improved quality control to greater scalability and flexibility. As manufacturers continue to embrace digital transformation, the synergy between MOM and MES will play a crucial role in driving operational excellence and achieving sustainable growth.