Development of a Methodology for Evaluating the Benefits of Implementing a Manufacturing Execution System

Manufacturing Execution Systems (MES) have become crucial in modern manufacturing, enabling companies to improve efficiency, monitor production processes, and optimize resource utilization. This thesis focuses on evaluating the benefits of MES implementation in One-of-a-Kind Production (OKP) companies, where production complexity and customization requirements pose significant challenges. The research is based on a case study of a company specializing in the fine-tuning phase of prototype manufacturing, a critical process that ensures the final product meets customer specifications. To assess the impact of MES, the evaluation objectives were first defined to ensure alignment with real industrial needs. The study then involved mapping the fine-tuning process to provide a comprehensive representation of its workflow, highlighting critical areas where MES data could offer the most significant improvements. Following the modelling of the process, a set of potential Key Performance Indicators (KPIs) was identified based on literature and industry best practices. The selection was then refined using the Fuzzy Analytic Hierarchy Process (Fuzzy AHP), allowing the identification of the ten most relevant KPIs for evaluating MES benefits. A systematic approach was then defined to calculate these KPIs using MES data, ensuring consistency and reliability in the evaluation. The study demonstrates how the MES enhances data availability and process monitoring in comparison with the previous system, thereby providing a more structured and reliable information base for decision-making. This enhancement facilitates enhanced tracking of production activities and a more precise identification of inefficiencies. Furthermore, the findings provide insights into how OKP companies can leverage MES to gain greater control over operations, improve traceability, and support a data-driven approach to process optimisation.