Strategic & Site MES Deployment

Global Site Deployment:
Let Seabrook help you find the best MES solution!

Deploying a Manufacturing Execution System (MES) or MES individual objects into a production environment, as with any other complex software, has risks associated with it. However, Seabrook Technology Group can help you to mitigate those risks! MES drastically changes the business process, and has a major impact on the daily business life of end users.

When implementing an MES successfully, communication is key. Successful MES implementation depends on gaining insights and input from every department that will ultimately be affected by an MES. Furthermore, Seabrook recommends that successful change management strategies be in place to ensure smooth transition and alignment between technology, personnel and existing business processes.

MES deployment is a complex endeavor, requiring a full project team. On average, MES deployment takes approximately six to twelve months depending on the complexity of the project. Additionally, the timeline and complexity are further impacted if MES is deployed in multiple sites.

Most multinational manufacturing operations that have multiple sites in various nations share information about manufacturing operations through an Enterprise Resource Planning System (ERP), or are transitioning to this model. For global manufacturers MES deployment is a major hurdle with many moving parts. Seabrook can help organizations roll out a standardized software application process management system to help global manufacturers regardless of size or location(s).

Strategic MES Consulting

1. Global MES Deployment

An MES deployment or MES individual objects into a production environment has risks associated with it, like other complex software processes. However, MES must be viewed through a different lens than other software implementations. MES has a profound influence on businesses process, similar to how operations used to. An MES will affect every user in their daily business life. Successful MES deployment needs input from every business unit that will be affected by implementation. Inputting successful change management strategies to align technology, people and processes.

2. MES Site Deployment

MES Deployment is complex and requires a full team. On average an MES Implementation takes 6 to 12 months depending on the complexity of the project. Multi-site MES deployment will lengthen these timelines due to complexity. Most multinational manufacturing operations that have multiple sites in various nations share information about manufacturing operations through an Enterprise Resource Planning System (ERP), or are transitioning to this model. For global manufacturers MES deployment is a major hurdle with many moving parts. Seabrook can help organizations roll out a standardized software application process management system to help global manufacturers regardless of size or location(s).

3. MES Integration

After successful MES integration and manufacturing process mapping, the next step is to monitor the process. Real-time visibility is the goal during manufacturing processes. Through analytics, reporting, KPIs and engineering data gaining information about the process is critical. The integration team is so important because depending on the IT application deployment process the data can vary from great, to poor. A great MES consultant can help ensure that all process-related information can be captured in real-time and the data can be elevated to the right people throughout the value chain.

MES Road Map

By integrating Enterprise Resource Planning (ERP) and manufacturing data for more accurate demand forecasts, companies can reduce inventories by avoiding overproduction. In today’s competitive global markets, a lean manufacturing process is more important than ever. Sharing information between the manufacturing floor and business systems enable manufacturers to achieve new levels of efficiency. Since Enterprise Resource Planning (ERP) systems contain information regarding inventory and customer demand, and Manufacturing Execution Systems (MES) control how to build it, integrating the two worlds dramatically increases operational efficiency, and enables organizations to be more flexible and responsible to customized and changing demands.

1. Mapping Physical Processes

The first step in this process is to have all physical assets involved in the manufacturing process mapped and outlined. MES application plays a vital role in establishing a clear picture of the current process, and it acts as a virtual connector for all process assets, while allowing for the flow to be documented, understood and improved.

2. Mapping Business Processes

Step two is key to an integrated value chain – which is geared to benefit from Industry 4.0. A clear and comprehensive understanding of how the functions connect with manufacturing internally and how the entire manufacturing function connects with other members of the value chain (such as the suppliers and customers) becomes extremely important to facilitate the digital transformation of the entire value chain. To have a truly Industry 4.0-enabled operation, it is critical to follow a roadmap which aims at digitized operation, but achieves it in a progressive and planned manner.

3. Gain Real-Time Visibility

After successful mapping of the manufacturing process, our next step is to monitor this process. Clear, real-time visibility should be the goal when monitoring the manufacturing process. This is gained through studying key performance indicators (KPI) and engineering data, reviewing online analytics, and generating reports. It is essential to note that depending on the IT application deployed in the process, the quality of information will vary greatly: from good – to bad – to completely unreliable. Because of this, it is absolutely critical to have the correct MES provider and consultant team to ensure that all process-related information can be captured in real-time and the data captured can be immediately elevated correct personnel throughout the value chain.

4. Optimizing Manufacturing Processes

With a solid foundational understanding of the manufacturing status quo and shifting attention shifting the process towards achieving a digital manufacturing operation, the next step is process optimization. During monitoring, discovering processes that need improvement are the areas to optimize to increase to generate value for the process. Processes are constantly examined and optimized including: production planning, process scheduling, yield management, pricing evaluation, and preventative maintenance. This stage is vital to the manufacturing process and it immediately displays the value of the MES application deployed in improved efficiency and effectiveness of the manufacturing goals.

5. Make the Operation “SMART”

After a successful mapping of the manufacturing process, the attention must be shifted to monitoring. Real time visibility is the goal, with the ability to look at KPIs, generate reports, and engineering data. A solid MES is the difference between good information and bad information – which makes all the difference in medical device manufacturing. Great MES consultants, like Seabrook, help ensure that you get the good information to drive better decision making and process improvement throughout the value chain.

MES ROI

Manufacturing Execution System (MES) solutions have the potential to generate efficiencies, improve productivity, and simplify compliance within the medical device manufacturing industry. This software provides the ability to schedule activity, deliver instructions to operators, and synchronize manual activities with automated processes. Its ability to integrate with medical device manufacturing computer systems, there is great opportunity to improve quality control, reduce deviation management, communicate with effective enterprise resource planning (ERP), manage equipment, and document floor activities for monitoring and reporting purposes. Benefits of MES include: greater regulatory compliance, lower production costs, a centralized point of information in line with good manufacturing practices (GMPs), real-time production visibility, and increased equipment efficiency.

For any medical device manufacturing company, return on investment in the main consideration when changing business operations. MES at a lower price point is making the breakeven and profit opportunities even more attractive. A shorter ROI is important for smaller or middle market manufacturers who do not have the long runways of large conglomerates. Lower-cost MES is providing all the MES benefits without disrupting cash flow.

When implementing a flexible and scalable MES solution, ROI is feasible within 18 months. It can be achieved through a combination of reducing working capital (i.e. materials and inventory), lowering direct costs, increasing reliability (therefore reducing downtime), improving operational efficiencies, and reducing manufacturing operation and supply chain risk.

With a reputation built on thirty years of succeeding together with our partners, we are a team of manufacturing technology experts and industry thought leaders bringing end-to-end manufacturing solutions (people, processes, and technology) together to enable operational excellence for medical device and biotech manufacturers.

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