Ümit Acar (Writer)
13 June 2024
MES and APS: Roles and Functions
Manufacturing Execution System , (MES):
- Role: MES is a system that monitors and controls manufacturing operations in real time. It is involved in processes such as production processes, machine performance, material utilization and quality control.
- Functions: Real-time tracking of production progress, machine condition monitoring and quality assurance supports material consumption and inventory accuracy with ERP integration.
Advanced Planning and Scheduling , (APS):
- Role: APS optimizes production schedules taking into account constraints such as machine capacities, labor availability and material supply. It aims for the most efficient use of resources and meeting delivery deadlines.
- Functions: Demand forecasting, production scheduling, resource allocation and capacity planning
Why APS cannot fully function without MES
APS needs accurate and up-to-date information to create effective production schedules. Without MES, APS will not have the necessary real-time data, resulting in inefficient planning.
Here are some reasons why APS cannot work optimally without MES:
1. Lack of Real-Time Data:
- Issue: APS needs real-time data on machine status, production progress and material availability. Without MES, APS operates with outdated information, leading to inefficient planning.
- Example: APS may schedule work to a machine that is in maintenance, resulting in production delays and missed delivery deadlines.
2. Faulty Scheduling:
- Issue: Without MES, APS cannot correctly account for machine downtimes, maintenance schedules or unexpected outages. This results in frequent rescheduling and low production efficiency.
- Example: An automotive factory may plan production runs without taking into account available machine capacities, leading to bottlenecks and waiting times.
3. Poor Quality Control:
- The problem: APS needs quality data provided by MES to detect and address quality issues. Without this data, APS cannot adjust schedules, resulting in high scrap rates and poor product quality.
- Example: In a tampon production line, large quantities of defective tampons are produced before quality problems in a machine are detected.
4. Ineffective Inventory Management:
- Issue: To plan material requirements, APS needs accurate inventory data based on production notification and consumptions that MES provides to ERP. Without MES, APS can face material outages or overstocking, both of which are costly and inefficient.
- Example: A factory may face production stoppages due to material shortages or face additional storage costs due to excess inventory.