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MES System Implementation, What Can Go Wrong?

Manufacturing Execution System (MES) is an essential software tool that helps manufacturers to achieve their production goals. It provides a real-time overview of the production process, from raw material handling to finished goods, enabling managers to make quick and informed decisions. With its ability to track and optimize production processes, MES implementation can help companies improve quality, efficiency, and cost-effectiveness.

However, despite the benefits, MES implementation can also pose challenges that could derail the project’s success. In this article, we’ll discuss some of the most common issues that can go wrong in MES system implementation and how to mitigate them.

Lack of Proper Planning

The first step to a successful MES implementation is proper planning. Without a clear understanding of the project’s objectives, resources, and timelines, it is easy to get off track. Some companies rush into MES implementation without first assessing their current system and processes, leading to poor implementation results.

To mitigate this, companies need to conduct a thorough assessment of their current processes, resources, and goals before beginning the implementation process. This includes evaluating the MES system’s compatibility with its current infrastructure and the ability to integrate with other systems.

Poor Communication

MES implementation involves multiple stakeholders, including production managers, IT professionals, and vendors. Poor communication among these groups can lead to misunderstandings, delays, and mistakes. For instance, the production team might not provide enough information to the IT department, leading to poor system configuration. The IT department may also not communicate clearly with the vendor, leading to compatibility issues.

To avoid poor communication, it’s important to establish clear communication channels and a project management structure that ensures all stakeholders are on the same page. Regular meetings, progress reports, and feedback sessions can help identify and resolve issues before they become major problems.

Resistance to Change

MES implementation can be disruptive, requiring changes to processes and workflows. This can lead to resistance among production staff who may feel uncomfortable with new systems and processes. Such resistance can slow down the implementation process or even derail it entirely.

To mitigate this, companies need to involve production staff in the MES implementation process from the beginning. This includes training them on the new system, showing them how it will improve their work, and listening to their feedback. When employees feel involved in the process, they are more likely to embrace the changes and work towards a successful implementation.

Insufficient Testing

Testing is a critical part of MES implementation, and insufficient testing can lead to costly mistakes. For example, if the system is not tested thoroughly, it might not work as expected, leading to production delays, quality issues, or even safety concerns.

To mitigate this, it’s important to conduct thorough testing at every stage of the implementation process. This includes functional testing, integration testing, and user acceptance testing. Testing should be conducted by qualified personnel with the appropriate skills and experience to ensure accurate results.

Poor Vendor Selection

Choosing the wrong vendor for MES implementation can lead to numerous problems. For example, a vendor might not have the necessary expertise, experience, or resources to implement the system effectively. Alternatively, they might not provide adequate support after the implementation, leaving the company without a reliable partner.

To avoid this, companies need to conduct proper due diligence before choosing a vendor. This includes evaluating their experience, expertise, references, and support structure. It’s also important to establish clear expectations and service level agreements to ensure the vendor meets the company’s needs and requirements.

Data Quality Issues

MES implementation relies on accurate data to function properly. If the data quality is poor, the system might produce incorrect or inconsistent results, leading to production delays, quality issues, or other problems.

To mitigate data quality issues, companies need to ensure that their data is accurate, complete, and consistent before implementing the MES system. This includes cleaning and standardizing data, establishing data governance policies, and providing adequate training to staff on data entry and management.

Inadequate Training

Inadequate training can be a significant barrier to MES implementation success. If production staff is not adequately trained on the new system, they might not use it correctly, leading to errors, delays, or quality issues.

To mitigate this, it’s important to provide adequate training to staff on the new system. This includes hands-on training, online training resources, and ongoing support. Training should be customised to the staff’s needs, roles, and responsibilities to ensure the effective adoption of the new system.


MES implementation can be a complex and challenging process, but with proper planning, communication, training, and vendor selection, it can be a powerful tool for improving production efficiency, quality, and cost-effectiveness. To ensure a successful implementation, it’s important to identify and mitigate the common issues that can go wrong, including lack of proper planning, poor communication, resistance to change, insufficient testing, poor vendor selection, data quality issues, and inadequate training.

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Łukasz Iskra

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