ERP vs MES systems – learn the differences and find the perfect solution

IT systems play an important role in managing business and operational processes in modern manufacturing. Among the most popular are ERP (Enterprise Resource Planning) systems and MES (Manufacturing Execution System) systems. When using and implementing these solutions, the question often arises,“Can ERP replace MES?” Or should MES take over some of the ERP functions? In this article, I suggest where these systems should find their place. ERP vs MES – learn the important differences!

To better understand how ERP and MES solutions should function, it is useful to look at the pyramid of industrial IT systems. It can be divided into four main levels:

As you can see, MES and ERP perform completely different functions, with ERP providing the overarching solution. However, the two systems work in symbiosis, working together to ensure operational efficiency.

System ERP (Enterprise Resource Planning) is a central enterprise management system. In the context of manufacturing companies, it can include:

ERP focuses on analyzing historical data and planning future activities. However, it does not operate on real-time data, which is one of the most important capabilities of MES systems.

The  MES(Manufacturing Execution System) system operates closer to the shop floor and is responsible for monitoring  processes inreal time. Its main tasks include:

MES does not plan production – it controls it. It is here that the actual parameters of the processes are analyzed, which makesit possible to react quickly to irregularities.

On my professional path I really often encounter the question“Shouldn’t the MES be part of the ERP?” In theory, one could try to extend the ERP system with production monitoring functions, but in practice such a solution is ineffective. Why?

As you can see, the differences between MES and ERP are significant. For this reason, the ideal solution is a synergy of both solutions. The MES system provides the operational data that ERP uses for strategic optimization.

Many companies are facing a dilemma:“Should we invest in a new ERP or implement an MES?” To make the implementation successful, it is worth approaching it strategically and comparing the needs of ERP vs MES implementation.

The best way to start is with adigital transformation workshop , during which:

Minimizing the number of IT systems is the key to efficiency. The fewer systems, the lower the maintenance costs, the fewer places for errors and the greater the transparency of processes.

MES and ERP are two completely different systems, but they work best when properly integrated. The MES system is responsible for monitoring and managing production in real time, while the ERP system collects data and allows for strategic management of the entire enterprise.

Instead of trying to replace one system with another, it makes sense to focus on their synergy. By doing so, a company can effectively automate processes, optimize costs, improve efficiency and make better business decisions.