Anyone searching for "MES system" or "collecting machine data" usually has one of two questions. Either: we want to control orders, materials and traceability on the shop floor digitally. Or: we finally want to see where our capacity is leaking away. Those are different problems, with different solutions and a very different project.
What an MES does
An MES sits between the ERP and the machines. It translates the plan into execution on the shop floor and records what happened per order.
- Releasing and tracking production orders per line and per workstation
- Work instructions and material consumption per order
- Recording what was made per order or batch, for traceability
- Reporting back to the ERP for planning and inventory
Because an MES changes the way the shop floor works and its link with the ERP, introducing one is an organisation-wide change: processes, roles and master data all move with it.
What a Smart Factory layer does
VDS Smart Factory reads data from your existing machines, PLCs and sensors via OPC UA, Modbus, I/O and APIs, and combines it with your ERP and MES. It measures passively: nothing is written into the controls and the way orders run does not change.
- Downtime and micro-stops per line, with their cause
- OEE per line and per shift, calculated automatically
- Quality drift, so you see a deviation before it turns into rejects
- Energy consumption per machine, linked to what was produced
Where they overlap: machine data
Many MES packages include a module for machine and production data acquisition, known in German as MDE and BDE: automatically recording downtime, cycle times and counters. That is exactly the part a Smart Factory layer also delivers on its own, without the order and planning side of an MES. If you mainly want to know where the time goes, that is enough.
Which one do you need?
An MES fits if you want to digitise execution itself:
- Orders, materials and work instructions need to reach the shop floor digitally
- Traceability per order or batch is mandatory and is done on paper today
- Planning and execution are two separate worlds today
A Smart Factory layer fits if you first want to see what is happening:
- You do not know where your capacity is leaking away
- Downtime is recorded by hand or not at all
- You want to see energy consumption per machine
- You already have an MES or ERP, but the figures are not real-time or not per machine
Many factories start with visibility: first measure where the losses are, then decide whether an MES is the right next step. By then you also know which parts of an MES you really need.
Alongside an existing MES
If you already have an MES, VDS connects to it and puts machine data next to order data. You then see, for example, downtime per order or per product, not just per machine. The data lives in your own Azure environment, so MES, ERP and machine data come together in one place.
Start small
With the one-line concept you put VDS Smart Factory on one line or installation within 6 to 8 weeks, with measurable results and a solid business case for the rest of the factory. Most projects start between €10,000 and €50,000.
Frequently asked questions
Is VDS Smart Factory an MES?
No. VDS does not control orders, planning or work instructions. It makes visible what happens on the shop floor and connects to your existing MES or ERP.
Do I need an MES to get started?
No. VDS reads directly from machines, PLCs and sensors. An MES or ERP is an extra source, not a requirement.
What is the difference between an MES and machine data acquisition?
Machine data acquisition (MDE/BDE in German) is the recording part: downtime, counters and cycle times. An MES also covers order control on the shop floor, work instructions and traceability per order.
Does VDS work with our existing MES?
Yes. VDS connects to ERP and MES systems and puts machine data next to order data, so you can see downtime per order or per product, for example.
How long does a first step take?
With the one-line concept you put VDS Smart Factory on one line or installation within 6 to 8 weeks, with measurable results.
