The manufacturing execution system (MES) originated as a replacement to paper-based process flows at a time when no one could have foreseen its potential to become a digital orchestrator of automated factories. This blog explores the journey of the MES from its origins to the present and imagines possibilities for the future.
The origins of MES: from artisanal to automated
Before the beginning of the Industrial Revolution in the 1700s, manufacturing was an artisanal process. There was no “mass production,” because each product was built from scratch based on tribal knowledge passed down through generations.
The turning point came in the late 18th century when inventor Eli Whitney introduced the concept of a written procedure to document the sequence of steps and parts required to build a product. This innovation enabled repeatability and mass production, laying the foundation for process change management and continuous improvement.
By the early 1900s, assembly lines became the physical representation of this process. Each workstation represented a single operation within the manufacturing process flow. At this stage, manufacturers had developed process instructions that could be replicated at each workstation. However, there was no effective method to reproduce the entire process flow for every item produced. Without a detailed record of each item’s manufacturing process, they had no way to ensure production was consistent, or to provide documentation for verification.
The commercial availability of the photocopier in the 1960s changed that. It enabled manufacturers to economically attach a copy of the process flow to each item. This allowed operators to record actions and enabled audits. This also paved the way for the MES as we know it today; the only missing piece was the computer.
The birth of MES: digitizing the process flow
The first MES emerged in 1976 as an extension of Computer-Aided Manufacturing (CAM) systems. These systems controlled Computer Numerical Control (CNC) tools and were designed to automate the machining of complex parts. The MES took this a step further by digitizing the entire process flow—replacing paper-based instructions with computerized records.
Early MES systems defined and controlled machining operations, ensured machined product flowed properly through the process flow, and recorded processing history. They introduced capabilities like data collection, specification definitions, and the ability to place product on hold during manufacturing. However, their primary function remained the same: replicating paper process flows in digital form.
As manufacturing grew more complex in the 1980s, the limitations of early MES software became apparent. Manufacturers wanted to integrate with external systems like Statistical Process Control (SPC) and automate equipment operations. MES vendors responded by creating customizable frameworks that allowed manufacturers to define process flows, manage equipment states, and track lots more flexibly.
MES at runtime: the power of lot tracking
Lot tracking represents the MES at runtime. The MES pairs a lot with a process flow, transforming static instructions into dynamic operations. Each step in the process flow has its own resource and data requirements. Some steps require processing equipment while others need chemicals or parts. As a lot progresses along its process flow, the MES records processing history, evaluates quality, and ensures compliance. This granular tracking enables manufacturers to guarantee that each item is built correctly and provides a digital trail for audits and analysis.
Beyond the basics: automating exception handling
Manufacturing isn’t always predictable. Non-standard scenarios—like out-of-spec measurements, failed tool processing, or engineering experiments—require manual intervention. These exceptions can disrupt productivity and introduce variability.
Modern MES systems, like the SmartFactory 300works MES, address this challenge by automating exception handling. Pre-built scenarios such as the Recovery Run Card and Experiment Run Card enable automated responses to many different types of exception conditions. Whether it’s reworking a lot, splitting a lot for parallel processing, or merging child lots, the MES exception handling scenarios ensure consistent and efficient lot processing.
This level of automation extends beyond product processing to include maintenance, qualifications, and R&D. In a lights-out factory, everything is automated, even non-product events, and this makes integration across the entire Computer Integrated Manufacturing (CIM) system critical.
The future of MES
As we look ahead, artificial intelligence tools will help the MES move from executing processes to optimizing them in real time. Innovations such as digital twins, predictive analytics, and autonomous decision-making will drive new capabilities. The MES will be able to anticipate failures, recommend corrective actions, and continuously improve operations.
Integration also will expand across the manufacturing ecosystem—from design and engineering to supply chain and customer service—with the MES serving as the backbone that connects disparate systems.
Conclusion
The journey of the MES from paper to digital, from reactive to proactive, has taken place in keeping with the evolution of manufacturing itself. As such, we can expect it to continue to evolve and redefine what’s possible in manufacturing.
As we embrace the future, the MES will continue to evolve, unlocking new possibilities and redefining what’s possible in manufacturing. Whether you’re building semiconductors, cars, or medical devices, the MES is your partner in progress —a silent force driving the smart factory revolution.
