How MES Transforms Manufacturing Operations and Slashes Costs
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Explore PLCnext TechnologyHosts Phil Seboa and Ed Fuentes are joined by MES specialist Matt Barber to discuss how MES systems are evolving in manufacturing, the challenges of implementing digital solutions, and the future impact of AI and machine learning on factory operations. Readers will find direct advice on why MES matters, what it takes to succeed with these systems, and which trends to watch as technology advances.
In today’s factories, the role of MES has shifted from a simple system for collecting production data to an essential tool that brings together different areas of manufacturing. Matt Barber points out that MES—once primarily about “executing production orders, collecting downtime, receiving counts and scrap”—now often covers areas such as quality assurance, maintenance management, inventory, and even energy tracking. He explains, “MES applications are slowly evolving to take on more and more MOM type functionality,” referring to Manufacturing Operations Management (MOM) as a broader strategy that ties together all operational needs.
This broader approach supports operators by giving them access to the essential data for their tasks, from running machines to quality checks and maintenance. The impact is visible across the shop floor, enabling quicker decisions and integrated processes. As MES systems grow to handle more MOM features, manufacturers get a fuller, real-time view of operations, making improvement and compliance much easier.
Implementing MES is about more than just installing new software—it requires a significant shift in mindset and habits. Matt Barber shares that many factories still rely heavily on paper and spreadsheets, creating silos and inefficiency. When organizations move to MES, “It’s a huge change for people and not an easy change.” Success depends on strong leadership, clear vision, and buy-in across all levels.
Change management becomes the biggest hurdle. Teams need clear communication about why MES is important and how it benefits everyone—not just managers. Barber stresses, “If everyone’s rowing in the same direction… you can make it happen. But if there’s friction then that makes it more challenging.” With sound strategy and people-focused management, manufacturers see gains in real-time visibility, faster issue detection, and continuous improvement possibilities.
MES platforms produce vast streams of operational data—an essential foundation for advanced analytics and AI. Matt Barber explains, “The data that is captured by MES…the real time granular level of data you capture from the shop floor… is rife for AI and ML models.” However, he also warns that manufacturing companies are careful with automation and advanced algorithms, especially on the production line—trust must be built over time.
While some manufacturers remain early in their MES adoption, others are beginning to connect these systems to AI, machine learning, and predictive analytics. The future holds smarter automation, but, as Barber notes, “people are still dipping their toe in the water with AI.” The technology’s impact will grow as confidence grows, thanks to the foundation laid by reliable MES solutions and a careful, stepwise approach to digital innovation.
"You can't just buy the software. It's much broader than that… The people and the change management, that's the thing that makes the biggest difference in the projects and that's the thing that can have the biggest challenge." – Matt Barber
MES has expanded from production tracking to include quality, inventory, and maintenance (00:02:21–00:04:27).
Successful MES implementation depends on careful change management and organizational alignment (00:05:27–00:06:34; 00:27:34–00:29:10).
The combination of MES and automation opens the door for AI and advanced analytics, but adoption is gradual and built on trust (00:18:12–00:21:32).
Manufacturers are adopting MES not just to monitor machines, but to unite their entire operation—quality, maintenance, and more—into a single system. This shift brings big gains, but only when teams are aligned and leadership is proactive about change. Those who establish a strong MES foundation are best equipped to take advantage of future technologies, including AI and predictive analytics. For manufacturing leaders, now is the time to review digital practices, invest in people-first strategies, and set clear goals for data-driven improvement.
Actionable suggestions:
Prioritize people and leadership engagement before committing to MES projects, and create a roadmap for gradual improvement.
Matt Barber is a globally recognized MES specialist who currently leads the MES business at Infor. With extensive experience supporting hundreds of manufacturers, he is known for making operational excellence accessible and is a passionate advocate for digital improvement and knowledge sharing across the manufacturing sector.
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