Manufacturing Management System (MMS)

A Manufacturing Management System (MMS), also known as Manufacturing Execution System

(MES), is a software solution that helps manage, monitor, and control the manufacturing
processes on the factory floor. The primary goal of an MMS is to ensure that production
operations are executed efficiently, with minimal waste, while maintaining high-quality
standards. It handles various aspects of production, such as scheduling, resource allocation,
quality control, production tracking, and performance analysis.

Top 5 Manufacturing Management Systems (MES)

1. Siemens Opcenter (formerly SIMATIC IT)

o Overview: Siemens Opcenter is a comprehensive MES solution that covers
various aspects of manufacturing operations. It integrates with other systems and
provides real-time data for decision-making.
o Key Features: Production scheduling, quality management, material tracking,
performance analysis, and integration with Siemens PLM software.
2. Rockwell Automation (FactoryTalk ProductionCentre)
o Overview: FactoryTalk ProductionCentre by Rockwell Automation is a highly
scalable MES that helps manufacturers manage and optimize production
processes.
o Key Features: Real-time monitoring, quality management, production
scheduling, and compliance management.
3. SAP Manufacturing Execution
o Overview: Part of SAP's larger suite of enterprise applications, SAP
Manufacturing Execution integrates seamlessly with SAP ERP and SCM systems.
o Key Features: Production order management, quality control, machine
integration, and detailed analytics.
4. Dassault Systèmes DELMIAworks (formerly IQMS)
o Overview: DELMIAworks offers a robust MES designed for manufacturing
environments, focusing on automation and real-time visibility.
o Key Features: Production management, quality control, inventory management,
and integration with ERP.
5. Honeywell Manufacturing Execution System
o Overview: Honeywell's MES solution is designed for process industries,
providing comprehensive tools to manage production, ensure quality, and
optimize operations.
o Key Features: Batch management, quality assurance, asset management, and
real-time analytics.

Integrating with a Manufacturing Management System (MES)

Integration of an MES with other enterprise systems is crucial for ensuring a smooth flow of
information across the organization. This integration typically involves connecting the MES with
ERP (Enterprise Resource Planning), PLM (Product Lifecycle Management), SCM (Supply
Chain Management), and other factory floor systems like SCADA (Supervisory Control and
Data Acquisition) or PLCs (Programmable Logic Controllers).

1. APIs (Application Programming Interfaces)

 Usage: APIs are commonly used to enable real-time data exchange between the MES and
other systems like ERP or SCM.
 Integration Example: An API can be used to send production orders from the ERP
system to the MES and return production status updates back to the ERP in real-time.

2. Middleware

 Usage: Middleware solutions act as a bridge between different software systems,

ensuring seamless communication and data consistency.
 Integration Example: Middleware like TIBCO or MuleSoft can be used to integrate
MES with legacy systems or various third-party applications, managing data
transformation and protocol conversion.

3. OPC (OLE for Process Control)

 Usage: OPC is an industry-standard protocol for communication between industrial

automation devices and software systems.
 Integration Example: MES can be integrated with PLCs and SCADA systems using
OPC, allowing for real-time data collection from the factory floor for monitoring and
control purposes.

4. Custom Integrations

 Usage: Custom-built connectors or scripts are sometimes necessary when standard

integration methods do not meet specific requirements.
 Integration Example: A custom integration might be developed to connect a proprietary
machine control system with the MES to ensure accurate data capture and processing.

5. Database Integration

 Usage: Direct database integration can be used to share data between MES and other
systems where APIs or middleware are not suitable.
 Integration Example: The MES can be integrated with the ERP system through direct
database queries, allowing for seamless data exchange such as inventory levels or
production schedules.

6. Cloud Integration

 Usage: For cloud-based MES solutions, cloud integration platforms (iPaaS) can be used
to connect the MES with other cloud or on-premises systems.
  Integration Example: Using an iPaaS like Dell Boomi or Azure Logic Apps, an MES
can be integrated with a cloud-based ERP, enabling real-time data synchronization and
process automation across platforms.

7. IoT Integration

 Usage: IoT devices and sensors on the factory floor can be integrated with the MES to
provide real-time data on machine performance, environmental conditions, and other
critical metrics.
 Integration Example: Integrating IoT sensors with MES allows for predictive
maintenance and real-time monitoring of production processes, reducing downtime and
improving efficiency.

Key Considerations for MES Integration

 Data Consistency: Ensuring that data is consistent across all integrated systems is crucial
for accurate reporting and decision-making.
 Scalability: The integration solution should be scalable to handle increased data volumes
as the organization grows.
 Security: Proper security measures should be in place to protect sensitive production data
during integration.
 Compliance: The integration should adhere to industry standards and regulations,
especially in highly regulated industries like pharmaceuticals or food manufacturing.
 Real-time Processing: For critical manufacturing operations, real-time data exchange
and processing are essential to maintain operational efficiency.
 Customization: Be prepared to customize integration points to fit the specific needs of
your manufacturing environment.

All Key Points:

When integrating a Manufacturing Management System (MMS) or Manufacturing Execution

System (MES) with other enterprise and factory systems, there are several critical integration
points to consider. Each integration point ensures that data flows seamlessly between systems,
enabling efficient and synchronized manufacturing operations.

1. Enterprise Resource Planning (ERP) Integration

 Purpose: Synchronizes manufacturing operations with business processes like finance,

procurement, and supply chain management.
 Integration Points:
o Production Orders: Transfer of production orders from ERP to MES.
o Material Management: Synchronization of material requirements and inventory
levels.
o Work Orders: ERP-generated work orders are sent to MES for execution.
o Cost Reporting: Transfer of production cost data from MES to ERP for financial
reporting.
 o Resource Planning: Synchronization of human and machine resources.

2. Supply Chain Management (SCM) Integration

 Purpose: Ensures that manufacturing operations align with supply chain activities such
as procurement, logistics, and distribution.
 Integration Points:
o Inventory Management: Real-time inventory data exchange between MES and
SCM.
o Supplier Collaboration: Synchronization of supplier orders and deliveries.
o Demand Planning: SCM demand forecasts are used to adjust production
schedules in MES.
o Logistics Coordination: Coordination of finished goods shipment with logistics
providers.

3. Product Lifecycle Management (PLM) Integration

 Purpose: Connects product design and engineering with manufacturing operations.

 Integration Points:
o Bill of Materials (BOM): Transfer of BOMs from PLM to MES for production
execution.
o Change Management: Synchronization of engineering changes between PLM
and MES.
o Product Specifications: Ensure that MES uses up-to-date product designs and
specifications.
o Quality Control: PLM data used for quality assurance during manufacturing.

4. Supervisory Control and Data Acquisition (SCADA) Integration

 Purpose: Provides real-time monitoring and control of production processes on the

factory floor.
 Integration Points:
o Process Data: Real-time data exchange between SCADA and MES for process
monitoring.
o Alarm Management: Synchronization of alarm events and notifications.
o Production Monitoring: SCADA data used for real-time production tracking in
MES.
o Performance Analysis: SCADA data integrated with MES for OEE (Overall
Equipment Effectiveness) analysis.

5. Programmable Logic Controllers (PLC) Integration

 Purpose: Direct integration with machinery for real-time control and data acquisition.
 Integration Points:
o Machine Control: MES sends control commands to PLCs to execute production
tasks.
 o Sensor Data: Real-time sensor data from PLCs is used by MES for monitoring
and quality control.
o Machine Status: PLC data on machine status and performance integrated with
MES.
o Preventive Maintenance: Use PLC data for predictive and preventive
maintenance scheduling.

6. Quality Management System (QMS) Integration

 Purpose: Ensures that manufacturing processes adhere to quality standards and

regulations.
 Integration Points:
o Quality Inspections: Synchronization of quality inspection data between QMS
and MES.
o Non-Conformance Reporting: MES reports production non-conformances to
QMS for corrective actions.
o Traceability: Integration for end-to-end product traceability.
o Compliance Reporting: Exchange of compliance data between QMS and MES.

7. Human Resources Management System (HRMS) Integration

 Purpose: Aligns workforce management with production requirements.

 Integration Points:
o Shift Scheduling: Synchronization of workforce schedules between HRMS and
MES.
o Labor Tracking: Real-time tracking of labor hours and productivity.
o Skill Management: Ensure that only qualified personnel are assigned to specific
tasks.
o Attendance and Payroll: Integration for accurate labor cost calculation.

8. Warehouse Management System (WMS) Integration

 Purpose: Coordinates manufacturing operations with inventory and warehouse

management.
 Integration Points:
o Material Handling: MES instructs WMS on material movements required for
production.
o Inventory Updates: Real-time updates on inventory levels between WMS and
MES.
o Finished Goods Storage: Coordination of finished goods storage in the
warehouse.
o Order Fulfillment: Synchronization for timely order picking and shipping.

9. IoT Devices and Sensors Integration

  Purpose: Provides real-time data from factory floor equipment for monitoring and
optimization.
 Integration Points:
o Condition Monitoring: Integration of IoT sensor data for real-time condition
monitoring.
o Predictive Maintenance: Use IoT data for predictive maintenance scheduling.
o Environmental Monitoring: Track environmental conditions (temperature,
humidity) affecting production.
o Energy Management: Integration for monitoring and optimizing energy
consumption.

10. Business Intelligence (BI) and Analytics Integration

 Purpose: Enhances decision-making through data-driven insights.

 Integration Points:
o Production Data: MES production data fed into BI tools for analysis.
o Performance Metrics: Integration for tracking and analyzing key performance
indicators (KPIs).
o Custom Dashboards: Real-time production dashboards displaying MES data.
o Reporting: Automated generation of production and quality reports.

11. Cloud and Edge Computing Integration

 Purpose: Enables scalable, real-time processing and data storage across distributed
environments.
 Integration Points:
o Data Synchronization: Real-time synchronization of data between MES and
cloud platforms.
o Edge Processing: Real-time processing of production data at the edge before
sending to MES.
o Cloud Analytics: Use cloud-based analytics tools to analyze MES data.
o Disaster Recovery: Cloud integration for backup and disaster recovery.

12. Manufacturing Intelligence Systems Integration

 Purpose: Provides a unified view of manufacturing operations through advanced

analytics and visualization.
 Integration Points:
o Data Aggregation: Aggregation of data from MES and other systems into a
central repository.
o Real-Time Monitoring: Integration for real-time monitoring of manufacturing
KPIs.
o Predictive Analytics: Use of integrated data for predictive analytics and
forecasting.
o Continuous Improvement: Integration for tracking continuous improvement
initiatives.
13. Customer Relationship Management (CRM) Integration

 Purpose: Aligns manufacturing operations with customer demands and expectations.

 Integration Points:
o Order Management: Synchronization of customer orders between CRM and
MES.
o Customization Requests: Integration for managing customized production
orders.
o Delivery Tracking: Real-time tracking of production status for customer orders.
o Customer Feedback: Integration of customer feedback into production quality
processes.

14. Regulatory and Compliance Systems Integration

 Purpose: Ensures that manufacturing processes comply with industry regulations and
standards.
 Integration Points:
o Compliance Reporting: Integration for generating compliance reports based on
MES data.
o Audit Trails: Synchronization of audit trails between MES and regulatory
systems.
o Certification Management: Ensure that production processes adhere to required
certifications.

15. Energy Management Systems (EMS) Integration

 Purpose: Monitors and optimizes energy usage across manufacturing operations.

 Integration Points:
o Energy Usage Data: Real-time energy consumption data from MES integrated
with EMS.
o Cost Optimization: Synchronization for optimizing energy usage based on
production schedules.
o Sustainability Reporting: Integration for generating sustainability and energy
efficiency reports.

16. Digital Twin and Simulation Integration

 Purpose: Creates a virtual model of the manufacturing process for simulation and
optimization.
 Integration Points:
o Real-Time Data: Synchronization of real-time data between MES and digital
twin models.
o Process Simulation: Use of MES data to simulate and optimize manufacturing
processes.
o Scenario Analysis: Integration for running "what-if" scenarios to improve
production efficiency.
key objects or entities are involved:

When integrating a Manufacturing Management System (MES) or Manufacturing Execution

System (MES) with other enterprise systems, several key objects or entities are involved. These
objects represent the data, resources, and processes that need to be shared or synchronized
between systems. Understanding these objects is essential for effective integration.

1. Production Orders

 Description: Instructions to produce a specific quantity of a product within a defined

timeframe.
 Integration Involvement:
o ERP: Production orders are often created in the ERP system and sent to the MES
for execution.
o MES: MES manages the execution and provides real-time updates on the status of
production orders.

2. Bill of Materials (BOM)

 Description: A detailed list of raw materials, components, and sub-assemblies required

to produce a product.
 Integration Involvement:
o PLM/ERP: BOM is typically created in PLM or ERP systems and transferred to
MES for production planning.
o MES: MES uses the BOM to ensure the correct materials are used in production.

3. Work Orders

 Description: Specific tasks or operations assigned to workers or machines to complete a

production order.
 Integration Involvement:
o ERP: Work orders can be generated in the ERP and sent to MES for execution.
o MES: MES schedules and tracks the completion of work orders, updating the
ERP as necessary.

4. Inventory Data

 Description: Information about the quantity and location of raw materials, work-in-
progress (WIP), and finished goods.
 Integration Involvement:
o WMS/SCM: Inventory levels are managed in WMS or SCM and synchronized
with MES.
o MES: MES updates inventory levels as materials are consumed or products are
completed.

5. Machine Data
  Description: Real-time data from machines, such as operational status, performance
metrics, and maintenance needs.
 Integration Involvement:
o SCADA/PLC: Machine data is collected via SCADA or PLC systems and
integrated with MES.
o MES: MES uses machine data for monitoring, optimization, and predictive
maintenance.

6. Quality Data

 Description: Information related to the quality of materials and products, including

inspection results, defects, and compliance.
 Integration Involvement:
o QMS: Quality data is managed in QMS and shared with MES for process control.
o MES: MES collects and analyzes quality data during production and reports back
to QMS.

7. Labor Data

 Description: Information about the workforce, including attendance, productivity, skills,

and shift schedules.
 Integration Involvement:
o HRMS: Labor data is managed in HRMS and integrated with MES for workforce
scheduling.
o MES: MES tracks labor hours and productivity, sending data back to HRMS for
payroll and reporting.

8. Material Requirements

 Description: Detailed specifications of the materials required for production, including

type, quantity, and quality.
 Integration Involvement:
o ERP/SCM: Material requirements are defined in ERP/SCM and passed to MES.
o MES: MES uses this data to manage material usage and ensure availability.

9. Production Schedules

 Description: Timelines for completing specific production tasks or orders, often

including machine and labor assignments.
 Integration Involvement:
o ERP/SCM: Production schedules are often created in ERP/SCM and shared with
MES.
o MES: MES executes according to the schedule and provides real-time updates.

10. Performance Metrics

  Description: Key performance indicators (KPIs) such as Overall Equipment
Effectiveness (OEE), yield rates, and cycle times.
 Integration Involvement:
o BI/Analytics: Performance data is collected in MES and analyzed in BI systems.
o MES: MES tracks and reports performance metrics in real-time.

11. Compliance and Regulatory Data

 Description: Documentation and data required to meet industry standards and regulatory
requirements.
 Integration Involvement:
o QMS/ERP: Compliance data is managed in QMS or ERP and integrated with
MES.
o MES: MES ensures that production processes meet regulatory standards and
records compliance data.

12. Customer Orders

 Description: Orders received from customers specifying the products, quantities, and
delivery dates.
 Integration Involvement:
o CRM/ERP: Customer orders are managed in CRM or ERP systems and sent to
MES for fulfillment.
o MES: MES uses this data to prioritize production and ensure timely delivery.

13. Energy Usage Data

 Description: Information on the consumption of energy resources during manufacturing

operations.
 Integration Involvement:
o EMS: Energy usage is tracked in EMS and shared with MES for optimization.
o MES: MES monitors energy consumption and integrates with EMS for cost
management and sustainability reporting.

14. Environmental Data

 Description: Data related to environmental conditions in the manufacturing facility, such

as temperature, humidity, and air quality.
 Integration Involvement:
o IoT/SCADA: Environmental sensors collect data, which is integrated with MES.
o MES: MES uses environmental data to optimize production conditions and ensure
product quality.

15. Asset and Equipment Data

  Description: Information on the status, maintenance history, and utilization of
manufacturing equipment.
 Integration Involvement:
o CMMS/SCADA: Asset data is managed in CMMS or SCADA and shared with
MES.
o MES: MES tracks equipment usage and integrates with CMMS for maintenance
scheduling.

16. Production Reports

 Description: Detailed reports on production performance, including output, downtime,

and quality.
 Integration Involvement:
o ERP/BI: Reports are generated based on MES data and shared with ERP and BI
systems.
o MES: MES generates production reports for analysis and decision-making.

17. Audit Trails

 Description: Records of all actions and changes made during the manufacturing process,
used for compliance and traceability.
 Integration Involvement:
o QMS/ERP: Audit trails are stored in QMS or ERP and integrated with MES.
o MES: MES maintains detailed audit trails for regulatory compliance and quality
assurance.

18. Change Orders

 Description: Instructions for changes to be made to production processes, such as

engineering changes or process improvements.
 Integration Involvement:
o PLM/ERP: Change orders are created in PLM or ERP and sent to MES.
o MES: MES implements change orders and tracks their impact on production.

19. Machine Recipes

 Description: Predefined settings and parameters for specific production tasks or

products.
 Integration Involvement:
o PLM/SCADA: Recipes are developed in PLM or SCADA and integrated with
MES.
o MES: MES uses machine recipes to ensure consistent production quality.

20. Work Instructions

 Description: Detailed instructions for operators on how to perform specific tasks.

 Integration Involvement:
o ERP/PLM: Work instructions are created in ERP or PLM and shared with MES.
o MES: MES provides work instructions to operators and ensures compliance.