The Importance of Usability in a MES

From Paperwork to Productivity

Efficient industrial production management has always been a challenge, especially when relying on manual, paper-based processes. For decades, factories operated with scattered documentation, requiring manual data interpretation and transferring information into spreadsheets like Excel.

This process was not only time-consuming and error-prone but also demanded significant effort from operators and managers in analyzing collected data.

With the integration of technology in the industry, digitalization has introduced a new paradigm, simplifying data reading, analysis, and interpretation. Replacing paper with digital systems has made communication between different factory areas more efficient and faster. Now, an operator can be working on the production floor while a manager in their office has real-time visibility into factory operations.

In this context, Manufacturing Execution Systems (MES) play a crucial role in ensuring that information is managed and processed quickly and effectively. However, for an MES to be truly effective, usability must be a top priority.

Understanding user needs, recognizing their pain points, and stepping into their shoes are key to creating an MES that is usable, efficient, and enhances productivity.

The Impact of Usability on Industrial Production

Usability in an MES goes beyond software ease of use—it also involves how quickly users can interpret information. In an era of rapid technological advancement, MES solutions must offer intuitive interfaces.

An intuitive and well-structured system can provide:

• Reduction in human errors – Clear interfaces and simplified processes minimize mistakes, improving production quality.
• Faster learning curves – Consistent interfaces and well-defined operational standards help operators adopt the system more quickly.
• Quicker decision-making – Operators and managers can make informed decisions almost instantly, reducing downtime.
• Faster data input and processing – The quicker and smoother data recording is, the less time spent on administrative tasks and the greater the overall efficiency.
• Waste reduction and improved operational performance – Predicting material shortages before a product reaches the production line can prevent significant delays. Automated alerts and corrective action suggestions help teams solve problems before they impact productivity.

Scalability, Data Visualization, and Interpretation

A major usability challenge in an MES is managing the vast amount of data consulted daily. Scalability and data presentation must be carefully considered, adapting displays based on the device type (computer, tablet, or mobile phone) and the user’s role.

A good MES should ensure that information is displayed clearly and efficiently, allowing customization through filters that help users find relevant data without sifting through unnecessary information.

For example,

• A line operator may only need to see real-time production status.
• A production manager might require a broader overview, including inventory levels, deadlines, and machine efficiency.

Dashboards and reports tailored to each user’s needs ensure an efficient and productive experience.

A strong usability foundation in an MES also follows the ALCOA principles, which ensure proper data management:

• Attributable – Each data entry should be linked to a specific user and timestamp, ensuring traceability through digital signatures, PINs, or audit trails.
• Legible – Data should be easy to interpret, avoiding reading errors or ambiguity.
• Contemporaneous – Data must be recorded in real-time to ensure accuracy and relevance.
• Original – Entries should be made directly into the system, avoiding unnecessary copies or unauthorized modifications.
• Accurate – Data should reflect operational reality, enabling informed decision-making.

Industry 5.0 and UX (User Experience) Design

Industry 5.0 prioritizes the human factor in production, making user experience (UX) in MES essential for effective collaboration between people and technology.

For an MES to be truly effective, it should include:

• Integration with emerging technologies – IoT, AI, Augmented Reality, Robotics, and Big Data.
• Customization and configuration – User profiles, individual preferences, and skill-based system adaptations.
• Training support – Helping operators acquire new skills and adapt to technology.
• Sustainability – Tracking environmental impact, adopting sustainable practices, and ensuring regulatory compliance.
• Flexibility – Adapting to unexpected changes in production demand.
• Cybersecurity – Protecting company data with strong security measures.
• Operational safety – Ensuring worker safety by monitoring and managing accident risks.

These features make an MES more efficient, secure, and sustainable, supporting a human-centered, adaptable production environment.

Conclusion

The usability of a Manufacturing Execution System (MES) plays a crucial role in optimizing industrial production. The integration of digital technology has transformed production management, making it more agile and precise. However, for an MES to be truly effective, it must be intuitive, easy to use, and adaptable to the specific needs of its users, whether on the factory floor or in management.

A well-designed interface that enables clear and efficient data visualization reduces errors, speeds up decision-making, and enhances operational performance. Additionally, the system’s scalability and customization ensure flexibility, making it suitable for both operators and managers, fostering a more productive and collaborative experience.

Industry 5.0 further elevates the importance of usability by placing humans at the center of production. An MES must integrate emerging technologies, adapt to individual user needs, promote sustainability, and ensure data security and protection.

In summary, MES usability not only improves efficiency and safety but also contributes to a smarter, more agile, and human-centric production environment. By aligning with the principles of Industry 5.0, it empowers employees and enhances companies’ competitiveness in the global market.