MES Integration: The Real Challenge for ASEAN Factories

The Real Bottleneck in Low-Code MES Software isn’t the Code, It’s Integration \\[n]In a recent survey by Rockwell Automation, it was found that 93% of manufacturers across 17 countries, including those in ASEAN, are already using Manufacturing Execution Systems (MES). However, only 28% have implemented these systems enterprise-wide, and just 23% have fully integrated them with other critical systems like ERP, PLM, quality, and operational technology (OT). This highlights a significant gap between MES adoption and effective integration. \\[n]For factories in Thailand, Vietnam, Indonesia, and Malaysia, this means that while they may have the necessary software, the real challenge lies in ensuring seamless communication and data flow between different systems. This is particularly important as these countries aim to enhance their manufacturing capabilities and compete on a global scale. \\[n]### The Importance of Integration \\[n]Integration is not just a technical issue; it is a strategic one. According to the survey, 44% of manufacturers rank integration as their top MES buying requirement, and 33% cite it as their biggest data integration problem. Anthony Murphy from Rockwell Automation emphasizes that “MES adoption is no longer the hurdle, but enterprise scale is.” \\[n]This sentiment is echoed by earlier studies, such as the 2016 research on a Bandung steel plant, which identified functional integration as the most difficult challenge. For ASEAN factories, this means that while they may have the right tools, the real value comes from how well these tools can work together. \\[n]### The Role of Low-Code MES \\[n]Low-code MES solutions are often marketed as a new and innovative approach to solving these integration challenges. However, the concept of configurable MES systems has been around since 1997, when MESA International defined the category. The key difference is that low-code solutions offer more user-friendly interfaces for configuration, but they do not inherently solve the underlying integration issues. \\[n]For ASEAN manufacturers, this means that while low-code MES can simplify the process of setting up and configuring systems, the real work still lies in ensuring that these systems can communicate effectively with each other and with the machines on the factory floor. \\[n]### Machine Data Integration: The Critical Step \\[n]The real bottleneck in MES implementation is not in the code itself, but in the integration of machine data. On Time Edge’s Kim Burndred categorizes machines into two types: those with native connectivity (Category 1) and those that require an IIoT gateway (Category 2). For ASEAN factories, this means that before rolling out any MES solution, it is crucial to assess the connectivity of their existing machinery. \\[n]Research from TU Munich highlights the complexity of this task, with 989 lines of code required just for data collection across three lab machines. This underscores the need for a thorough assessment and planning phase, especially for brownfield sites where legacy equipment may be prevalent. \\[n]### The Role of Context in Connectivity \\[n]Simply turning on a protocol like OPC UA is not enough to ensure meaningful data exchange. Marcus Ilgner, after 18 months with OPC UA, found that the full model often goes unused due to the overhead it carries. For ASEAN manufacturers, this means that while protocols like OPC UA can provide the necessary connectivity, the real value comes from contextualizing the data. \\[n]Wautoma Biotech, an equipment OEM, describes this as the difference between providing a cable and providing a map. The contextualizing work, which involves mapping and interpreting the data, is the key to unlocking the full potential of MES. \\[n]### Takeaway for Factory Buyers \\[n]For ASEAN factory buyers, the takeaway is clear: while low-code MES solutions can simplify the setup and configuration process, the real challenge lies in ensuring seamless integration with existing systems and machinery. Before investing in a new MES, it is crucial to conduct a thorough assessment of your current infrastructure and plan for the integration of machine data. By focusing on this critical step, you can maximize the value of your MES investment and drive greater efficiency and productivity in your operations.