In the first three parts of our Digital Transformation Blog Series, we covered assessing operations, how MES links planning to production, and which MES features deliver the most value. Now in Part 4, we’re focusing on the infrastructure—networking, systems, and connectivity—and how we help manufacturers enable real-time data, scalability, and lasting transformation.
You could have the best MES software in the world, but without the right connections to ERP systems, control systems, and data storage, your tools will fall short. The value of digital transformation depends on seamless integration—and that requires modern, reliable infrastructure.
When all systems are connected, data flows securely and automatically:
From ERP to MES: Product formulations, work orders, and production plans are automatically sent to the MES.
From MES to control systems: Recipe parameters and operator instructions are transmitted to the shop floor.
From control systems to MES: Actual run data, material movements, downtime events, and production performance are captured and stored in context.
This end-to-end feedback loop is what allows for real-time decision-making, traceability, and performance optimization.
It’s true that MES can be deployed in a disconnected mode (i.e., not talking to your ERP or PLCs). But disconnected systems typically require manual data entry, duplicative processes, and don't scale well. The biggest benefit is unlocked when MES bridges your entire digital architecture.
With full integration:
Material consumption and production yield are automatically recorded.
Quality parameters and operator checklists are enforced.
Downtime events are tracked without operator intervention.
Real-time dashboards provide visibility into what’s happening across the plant—or across multiple plants.
This level of coordination and control isn’t just a technical upgrade—it’s a business advantage.
Not every plant is starting from the same point, and that’s okay. Some of the common challenges we help clients navigate include:
Older controls platforms that can’t natively communicate with new MES software
Manual reporting processes that consume valuable operator time
Inconsistent network infrastructure or missing device connectivity
We don’t expect your environment to be perfect. We identify the gaps and offer tailored solutions to bridge them. For instance:
Use a “data concentrator” PLC to pull production data from legacy systems.
Deploy manual entry forms to collect information until automated data sources are added.
Plan incremental hardware upgrades for high-impact areas first, such as key production lines or quality-critical systems.
Each remediation option is evaluated for cost, effort, and expected benefit—and it’s plotted in the same value vs. effort matrix from your operational assessment.
While the specifics vary by facility, here’s what a digitally ready manufacturing plant often includes:
Virtualized servers that are scalable and support multiple MES applications
Segmented and secure industrial Ethernet networks
A well-documented architecture with standard communication protocols (e.g., OPC UA, MQTT)
Industrial PCs or tablets that operators use to access MES screens, review instructions, or input quality data
Cloud-enabled or on-premise storage solutions with built-in redundancy and disaster recovery
Infrastructure like this isn’t just about tech—it’s about enabling fast change, reducing manual work, and giving decision-makers access to accurate data at the right time.
Think of your MES as the nerve center of your manufacturing operation. But it can only function as such when infrastructure allows it to:
Ingest production plans from ERP
Communicate instructions and parameters to PLCs and HMIs
Record data from equipment and people
Push insights to management and supply chain teams
This makes your MES a true integration layer between your business systems (top floor) and your automation systems (shop floor). But again—it all depends on infrastructure.
One of the biggest transformation mistakes we see is waiting for “perfect” infrastructure before implementing MES. Perfection is rarely possible, and it’s never required to start. The better strategy is to begin where the value is clear and expand as infrastructure evolves.
Our team works with you to:
Identify what functionality can be implemented today
Understand what gaps are blocking other features
Create a phased infrastructure improvement plan
You don’t have to do everything at once—but you should know what steps to take next.
Infrastructure might not be the flashiest part of digital transformation, but it’s one of the most important. Without reliable connectivity and integration, MES can’t deliver the visibility or performance you’re counting on.
That’s why Cybertrol looks at the big picture—from enterprise systems to plant-floor devices—to ensure you have the right infrastructure in place to support scalable, connected manufacturing.
In the final installment of this series (Part 5), we’ll bring everything together and show how we help clients create a realistic, actionable digital transformation roadmap.
This is Part 4 of 5 in Cybertrol’s Digital Transformation Blog Series. Stay tuned for the final installment, where we’ll talk about how to prioritize, phase, and execute your transformation plan.
Did you miss Parts 1, 2, or 3? Read them now!👇