Replacing or upgrading a Manufacturing Execution System (MES) is a major strategic decision—especially for multi-site manufacturers. The wrong choice can result in missed functionality, integration headaches, cost overruns, and extended downtime.
The High Stakes of MES Replacement
Each production facility brings its own workflows, quality processes, equipment integrations, and compliance requirements. Without a structured, vendor-neutral evaluation, organizations risk investing in a system that fails to meet critical needs or scale effectively across the enterprise.
Cybertrol’s MES 2.0 Engineering Study eliminates that risk through a proven, data-driven process that identifies the best technical and operational fit before implementation begins.
Why a Structured MES Study Matters
Too often, MES selection is driven by vendor presentations, incomplete information, or assumptions about “industry best practices” that don’t reflect actual plant operations.
A structured MES study ensures decisions are based on real-world requirements. This approach uncovers operational needs across all facilities, aligns IT and operations teams, and provides a side-by-side evaluation of leading MES platforms.
Cybertrol's MES 2.0 Engineering Study Process
Our study follows a seven-step methodology designed to uncover every requirement, score each platform against those needs, and deliver a complete decision package.
- Collect Requirements – Facilitate workshops with stakeholders in all functional areas to gather detailed MES needs from a baseline site, noting any site-specific requirements from other locations.
- Prepare URS Documents – Compile all requirements into a comprehensive User Requirements Specification (URS) to serve as the foundation for platform evaluation.
- Review for Awareness – Share initial findings with stakeholders to ensure all operational and technical needs have been accurately captured.
- Refine for Accuracy – Incorporate stakeholder feedback to clarify, adjust, or expand requirement details for precision.
- Validate for Acceptance – Secure formal agreement on the URS content to establish a clear and approved scope for evaluation.
- Align with All Stakeholders – Confirm that operations, IT, engineering, and leadership are in agreement on priorities, evaluation criteria, and success measures.
- Present Results – Deliver the final study results, including platform compatibility scoring, budgetary estimates, and Cybertrol’s engineering recommendations.
What’s Evaluated During an MES Study
The analysis compares how each MES platform performs against critical decision factors, including:
- Interoperability – Native connectivity to control systems
- Multi-Site Capability – Enterprise and site-level visibility
- Traceability – Raw material to finished goods tracking
- Reporting and Analytics – Automated dashboards and reports
- Security and IT Compliance – Cloud, hybrid, or on-prem architectures
- Redundancy and Availability – High-availability options for critical operations
- Support Models – 24/7 coverage, SLAs, and vendor responsiveness
- Customization Flexibility – Code ownership and extensibility
Deliverables from the MES 2.0 Engineering Study
By the end of the study, decision-makers receive:
- Executive Summary – High-level findings and recommendations
- URS Documentation – Full functional requirements for all facilities
- Compatibility Scores – Objective scoring of each platform’s capabilities
- Budgetary Estimates – Detailed cost projections for each option
- Final Recommendations – The platform that best meets operational and business goals
The Outcome: Reduced Risk and Increased Confidence
A data-driven MES selection process provides:
- Stakeholder alignment before implementation begins
- Clear understanding of trade-offs between platforms
- Accurate cost projections
- Reduced risk of rework, scope creep, and costly surprises
Whether the outcome points to Rockwell Automation’s Plex or FactoryTalk Optix, Ignition by Inductive Automation, or another MES platform, the decision will be backed by comprehensive technical and business analysis.
Ready to evaluate your MES options? Start with a structured study that gives you the data and confidence to choose the right path—contact Cybertrol to begin.