MES implementation for a client

Initial situation

A leading manufacturer of window modules with a central production site realized highly customized projects, primarily for complex construction projects in the United Kingdom. The company operated without an integrated ERP system. Metal fabrication, welding, painting, and assembly were not sufficiently interconnected. This resulted in missing parts at the construction site, disruptions in project execution, and high contractual penalties from construction companies. At the same time, customers expected the highest adherence to deadlines and uncompromising quality.

What we implemented

Establishing integrated planning across the entire value stream

By implementing a Manufacturing Execution System (MES) and integrating it bidirectionally with ERP and warehouse management, end-to-end planning across the entire value stream was enabled. Work orders could be consistently planned, released, tracked, and prioritized – from order release to delivery. Additionally, workforce planning was linked to operational demands, allowing resource management to be much better adapted to actual utilization.

More connectivity, transparency, and better decisions

The seamless connection of machines created the basis for reliable performance monitoring, alerts, and objective performance analyses. Material movements and deviations could be tracked in real-time, significantly increasing transparency in operational processes. Simultaneously, a reliable data foundation was established for more precise manufacturing cost calculations and CO₂-related evaluations. This enabled decisions to be made fact-based and significantly faster.

Digitization of production-related documentation

All production-relevant documents were digitized – including documentation, work instructions, and production logs. This reduced manual effort, improved information availability, and increased traceability across all process steps.

Result

With the introduction of MES across all operational areas, real-time transparency was achieved – from order release to delivery. Prioritization and control could be directly anchored in value-adding processes. This empowered managers to control execution significantly more effectively and fact-based.