According to the Scaling MES Across the Enterprise Report, manufacturers have largely acknowledged the benefits of Manufacturing Execution System (MES) adoption — and are taking action. In fact, this recent global survey of more than 1,500 leaders in manufacturing reveals that manufacturers have crossed the adoption threshold and, as the name of the report suggests, now face the strategic work of scaling?
93% of manufacturers report having MES in place, only 23% say it is fully integrated across their operations — leaving significant value unrealized across the enterprise.
But what exactly is standing in the way of this important and valuable work? Many manufacturers are finding that disconnected systems, underutilized data and rising complexity are limiting their ability to operate at scale. At the same time, the rapid acceleration of AI and increasing operational risk are raising the stakes for modern manufacturing systems.
In addition to shedding light on key trends in MES, this new report also provides insights on how manufacturers can take action, including step-by-step considerations based on the research. Below is a breakdown of these steps along with some additional resources, including our Proven Playbook for Scaling MES with Plex.
Moving from deployment to enterprise-wide performance
Step 1: Standardize MES across sites.
Half (51%) have scaled MES across multiple locations with standardization. The shift from implementation to operationalization is now the defining challenge. Manufacturers have moved past the question of deploying MES and now focus on making it work consistently across the enterprise.
Step 2: Prioritize integration from start.
Integration ranks as both the #1 MES buying requirement (44%) and the top modernization challenge.
Integration ranks as both the #1 MES buying requirement (44%) and the top modernization challenge. However, the majority of MES deployments are functioning in partial isolation, limiting the data flows and operational visibility that make MES transformative. The organizations that succeed will be those that treat integration as a foundational design principle rather than a downstream activity.
Step 3: Align ownership across functions.
Scaling MES is as much an organizational challenge as it is a technology one. Once a system's connectivity is in place, coordination becomes the next imperative. Manufacturers must align teams, governance and decision-making across IT, OT and operations teams to standardize and execute successfully.
Step 4: Turn data into operational insight.
43% of manufacturers acknowledge they are falling short of using their collected data effectively.
43% of manufacturers acknowledge they are falling short of using their collected data effectively. Collecting data is the starting point. Using it is the real challenge. After building the systems and processes to gather data consistently, manufacturers must move beyond simple visibility to gain real-time, actionable insights that inform decisions on the plant floor.
Step 5: Build for AI-ready operations.
42% of manufacturing processes are set to become AI-supported within the next year. The elastic operational foundation that AI requires to perform at scale is not evolving at the same pace. AI is advancing faster than the data infrastructure required to sustain it.
Step 6: Embed resiliency into the system.
Nearly half (46%) of manufacturers experienced a cyber incident in the past year.
Nearly half (46%) of manufacturers experienced a cyber incident in the past year. Greater connectivity brings greater exposure. The manufacturers building resilient operations understand that systems that embed protection, visibility and adaptability directly into the execution layer are structurally different from systems that layer those capabilities on after deployment.
Step 7: Empower employees to operate differently.
More than one-third (37%) of manufacturers identify change management as a key workforce obstacle. Manufacturers must equip their workforce with the tools, training and processes needed to act on real-time data and operate in more connected, automated environments. Building this training layer is an ongoing activity to enable continuous learning and improvement.
Ready to take your MES beyond deployment? Explore our playbook for proven strategies, practical guidance and inisghts to help you scale MES across your organization and drive greater enterprise-wide performance:
Proven Playbook for Scaling MES with Plex
Get the resources you need to help you move from MES deployment to enterprise-wide performance.
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