Global Site Deployment: Let Seabrook help you find the best 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.

Communication is key when implementing MES.  Successful deployment of an MES system depends strongly on obtaining input from every department that is affected by its introduction.  Additionally, we recommend that successful change management strategies be in place to ensure smooth transition and alignment of technology, people, and 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 major manufacturing companies operating from multiple sites – often in multiple countries and  continents – have already standardized manufacturing operations on an enterprise resource planning (ERP) system – or are in the process of doing so. For global manufacturers then, the view of MES deployment can be a major hurdle, as manufacturers with multiple production plants globally wish to standardize the software application for process management.  Seabrook can aid in this deployment, regardless of the size or global status of the organization.

Strategic Consulting

1. Global Deployment

Deploying an MES system or MES individual objects into a production environment, as with any other complex software, has risks associated with it. However, MES cannot be viewed in the same way as other technology-based system implementations. MES drastically changes the business process in the same way that operations used to, and as such, has a major impact on the daily business life of end users. Communication is key when implementing MES.  Successful deployment of an MES system depends strongly on obtaining input from every department that is affected by its introduction.  Additionally, we recommend that successful change management strategies be in place to ensure smooth transition and alignment of technology, people, and business processes.

2. Site Deployment

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 major manufacturing companies operating from multiple sites – often in multiple countries and  continents – have already standardized manufacturing operations on an enterprise resource planning (ERP) system – or are in the process of doing so. For global manufacturers then, the view of MES deployment can be a major hurdle, as manufacturers with multiple production plants globally wish to standardize the software application for process management.  Seabrook can aid in this deployment, regardless of the size or global status of the organization.

3. Integration

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. Validation

Medical device companies require successful implementation of quality engineering and validation to ensure that products consistently meet customer and patient needs. In the world of medical device design, expertise in MES deployment is a prized commodity.

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.

Step 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.

Step 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.

Step 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.

Step 4: Optimization of Manufacturing Processes

Once the current state of manufacturing/ status quo is clearly understood, the process towards attaining a digital manufacturing operation can move forward. The next stage in the road map, then, is process optimization:  improving the areas of the operation which were identified through the previous monitoring stage. Process optimization involves making incremental changes to the production process in order to improve performance and generate value.  During this stage, all processes are examined and optimized, including production planning, process scheduling, yield management, pricing evaluation and preventative maintenance.  Because this stage is vital to manufacturing success, it becomes obvious that an MES application deployed in the process greatly improves efficiency and effectiveness of organizations manufacturing goals.

Step 5: Make the Operation “SMART”

The final stage of the roadmap leads directly to optimized Industry 4.0!  This stage creates a complete virtual tour of the production floor, which paves the way for virtual reality scenarios to be implemented throughout the production process. The improvement made at this level has the potential to completely transform the current production flow and planning.


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 class of software provides the ability to schedule activity, deliver instructions to operators, and synchronize manual activities with automated processes.  Due to its ability to integrate with 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 business, return on investment (ROI) is the main consideration when evolving business operations. It is often thought that ROI can only be achieved in the long term, but the availability of MES options at a lower price point is changing that perception. Experiencing an ROI within a shorter time frame is particularly important for smaller medical device companies, which often work with less capital. Lower-cost MES is enabling these organisations to access the 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.

Questions?  Let us help!  We have partners and clients who have experienced tremendous ROI through MES deployment and Seabrook’s services.  For more information, simply contact us at the link below, or call Tel: +353 21 4800 840 (UK) or Tel: +1 317 426 0699 (US)