MES system integration: Optimizing your production

MES system integration: Optimizing your production

Michael Möller
Michael Möller
8 min
March 11, 2024

Learn how to increase production output and optimize processes through efficient integration of an MES system.

You'll be surprised how much influence efficient integration of a Manufacturing Execution System (MES) can have on your production output. Process optimization using MES integration enables you to optimize your processes and make your company even more successful. Read this article to learn how to implement this integration and take advantage of the benefits for your production.

Key findings:

  • Support for process optimization through MES integration
  • Benefits of seamless integration of MES software and data
  • Step-by-step guide to successful MES integration
  • Dealing with MES integration challenges
  • Proven best practices for successful MES integration

MES integration overview

In this section, we give you a comprehensive overview of MES integration. We will explain exactly what this means and what advantages an automated and process-integrated MES solution offers.

MES integration refers to the process by which a Manufacturing Execution System (MES) is seamlessly integrated into a company's existing infrastructure. The aim is to optimize the efficiency of production processes and to ensure better control over the entire manufacturing process.

Automating the process offers numerous advantages. By integrating various production processes, operational processes can be streamlined and errors reduced. As a result, the quality of manufactured products is improved and processing times can be reduced.

Process integration enables seamless communication and a seamless flow of data between different departments and systems. This increases transparency across the entire value chain. MES integration can also improve data collection and analysis, which enables informed decision making and effective resource planning.

An automated and process-integrated MES solution can help companies optimize their production performance and reduce their operating costs. It enables efficient use of resources and a faster response to changing market requirements.

With such integration, companies can achieve higher efficiency, better product quality, and bring their products to market faster. By automating production processes and integrating various processes, MES solutions provide a solid basis for success in an increasingly competitive business environment.

Benefits of MES integration

Increasing the efficiency of production processes

Reduce errors and improve product quality

Shorter turnaround times

Improved communication and data flow between different departments and systems

Increased transparency along the value chain

Better data collection and analysis for informed decision making

Effective resource planning and cost optimization

Get products to market faster

Benefits of MES integration

In this section, we will show you the various benefits of MES integration. Efficient integration of your MES software and data can lead to a wide range of improvements and optimizations in your production and workflows.

By seamlessly integrating your MES systems and data, you can:

  • increase production output
  • improve the efficiency of your work processes
  • Get real-time information about the current production status
  • Identify and resolve deviations and bottlenecks at an early stage
  • Reduce error rates and improve quality
  • increase transparency in your production
  • base decision making on well-founded data

With full MES integration, you can optimize your production and make your business processes more efficient. The smooth flow of information and data between your various systems allows you to gain a comprehensive overview of the production process and make informed decisions to achieve your goals.

MES integration gives you the opportunity to better plan your production, predict bottlenecks and react in good time to minimize downtime. It also enables effective resource management and optimal utilization of your manufacturing capacities.

Step-by-step instructions for MES integration

Here we offer you step-by-step instructions for successful MES integration into your company. Optimum integration of your manufacturing execution system can lead to more efficient processes and increased production output. Follow the steps below to successfully implement your MES integration:

  1. Preparation: Analyze your existing systems and identify integration requirements.
  2. Determination of needs: Define clear goals and requirements for MES integration.
  3. Choose the right solution: Evaluate various MES systems and choose the one that best suits your requirements.
  4. planning: Create a detailed plan for implementing MES integration in your production environment.
  5. Test phase: Perform extensive testing to ensure that the integration works smoothly.
  6. implementation: Implement the integration in accordance with the defined plan and ensure that all relevant data and processes are integrated.
  7. Monitoring and optimization: Continuously monitor the performance of integrated systems and make improvements as needed.

With this step-by-step guide, you are well prepared to achieve successful MES integration in your company. Don't forget that careful planning and a comprehensive testing phase are critical to identify and fix potential issues early on.

Integration steps



Identification of integration requirements and analysis of existing systems

Determination of needs

Define clear goals and requirements

Choose the right solution

Optimum adjustment to the requirements of the company


Detailed integration implementation plan

Test phase

Ensuring seamless integration


Integrate relevant data and processes

Monitoring and optimization

Continuous review and improvement of integrated systems

MES system integration challenges

Integration and execution can be associated with various challenges for companies of different industries and sizes. Below, we'll look at some of the most common MES integration challenges and provide valuable tips on how to successfully overcome them.

1. Complexity of integration processes

Integrating an MES system into existing production processes requires comprehensive analysis and planning. The complexity of integration processes can pose both technical and organizational challenges. It is important to carefully examine all areas and processes involved and to provide the right resources to ensure a smooth integration process.

2. Data consistency and quality

The integration of the MES system requires the exchange of data between various systems and components. One of the biggest challenges is ensuring a consistent and high-quality data source. Data inconsistencies or incorrect data can impair the efficiency of your production and lead to incorrect decisions. Thorough verification of data integrity and implementation of data validation mechanisms are therefore crucial.

3. Adaptation to existing workflows

Another common problem when integrating the MES system is adapting to existing workflows and operating procedures. Every company has individual working methods and processes that must be taken into account. The integration should therefore be designed in such a way that it can be seamlessly integrated into your existing workflows without disrupting operations or interrupting workflow.

4. Technical challenges

The technical aspects of integrating the MES system can also lead to challenges. The compatibility of the various systems, the adaptation to the IT infrastructure and the guarantee of data security are just a few examples of technical challenges that must be overcome. A comprehensive analysis of technical requirements and cooperation with experienced IT experts can be helpful here.

5. Change management

Integrating the MES system often requires changes in working methods and processes. Change management therefore plays an important role in preparing employees for the new technology and the changed processes. Open communication, training, and training programs can help to minimize resistance to change and ensure smooth integration.

6. Costs and resources

The integration of an MES system requires financial investments and the use of resources. The costs of purchasing, implementing and maintaining the system and training employees must be considered. It is important to realistically assess the available resources and ensure that the integration of the MES system is profitable in the long term.


Coping tip

Complexity of integration processes

Thorough analysis and planning, provision of appropriate resources

Data consistency and quality

Verifying data integrity, implementing data validation methods

Adaptation to existing workflows

Integration seamlessly into existing working methods, take operational processes into account

Technical challenges

analysis of technical requirements, collaboration with IT experts

Change Management

Open communication, training, training programs

Costs and resources

Realistic assessment of available resources, check long-term profitability

Best practices for successful MES integration

Here is an overview of proven best practices to ensure successful integration of your MES (Manufacturing Execution System) and optimize your production. Seamless integration results in efficient process integration and data integration to improve your business operations.

  1. Define clear goals and requirements: Before you start MES integration, define clear goals and requirements that you want to achieve. Identify the challenges and weaknesses in your current processes and determine how integration can help you overcome and improve them.
  2. Create an implementation plan: Develop a detailed implementation plan for MES integration Define milestones, time frames, and responsibilities to efficiently manage the integration process and ensure that all necessary steps are completed.
  3. Choose the right software solution: Choose an MES software solution that meets your specific requirements and provides seamless integration. Make sure the software is flexible, scalable, and adaptable to meet future needs.
  4. Train and educate your employees: Make sure that your employees are aware of the benefits of MES integration and receive the necessary training to use the new software effectively. Comprehensive training and communication supports successful integration and acceptance of the system.
  5. Validate the integration: Perform extensive testing to ensure that the integration is successful and works smoothly. Verify data integrity and the nature of process integration to identify and fix potential problems early on.
  6. Continuous improvement: MES integration is a continuous process. Monitor performance, analyze data, and identify areas where further optimization can be done. Conduct regular evaluations to ensure that your processes are constantly being improved and adjusted.

By following proven MES integration best practices, you can ensure that your production processes become more efficient and your business achieves optimal results.

Best Practice


Define clear goals and requirements

- Identification of challenges and weak points

- Improving business processes

Create an implementation plan

- Efficient management of the integration process

- Ensuring that all steps are carried out

Choose the right software solution

- Seamless integration

- Flexibility and scalability

Train and inform employees

- Knowledge about the benefits and use of the software

- Acceptance of the system

Validate integration

- Successful and smooth integration

- Early detection and resolution of problems

Continuous improvement

- Process optimization

- Adapting to changing requirements

The role of MES software in integration

MES software plays a decisive role in integrating the MES system. It enables seamless connection and interaction between the various components of your manufacturing execution system. Efficient integration of MES software ensures smooth communication and data transfer between the individual systems and thus enables optimal control and monitoring of your production processes.

The MES software should have certain functions and features to enable efficient integration. This includes:

  • MES integration: The software should be able to easily fit into your existing system and integrate with other systems such as production planning, warehouse management, and quality management.
  • MES software integration: It should allow easy integration with other software solutions and tools to seamlessly exchange data and support interactive workflows.
  • MES data integration: The software should be able to collect, process and analyze data from various sources in order to uncover valuable insights and optimization potential.

Presentation of the most important functions of MES software integration



data processing

The software should be able to process large amounts of data in real time in order to efficiently control production processes.

workflow control

It should enable the automation and control of work processes to ensure smooth production.

Real time monitoring

The software should be able to monitor the current state of production in real time and be able to intervene if necessary.

With well-integrated MES software, you can optimize the performance of your production and increase your efficiency. Efficient integration gives you greater control over your processes and a better response to change. Invest in powerful MES software integration to gain competitive advantages and make your business successful.

Case studies of successful MES integrations

In this section, we present case studies of successful MES integrations. Find out how well-known companies have improved their production processes through optimized process integration and benefited from the advantages of MES integration, MES automation and MES process integration.

Isi Group from Austria

The iSi Group describes itself as the world market leader in the area of compressed gas cylinders. The company was founded in Vienna in 1867 and sells its products to more than 90 countries.

iSi used a specially developed MDE solution to collect machine data in the culinary sector. However, due to the diversity of the machine park, individual stand-alone solutions were created in order to obtain access to the relevant data from the machines. Over time, however, the in-house development no longer met the company's requirements for modern machine data collection.

After completing the selection process, iSI had two options available: The first option was a tailor-made system that was specifically tailored to the company's requirements. The second option was to use BiSoftMES from gbo datacomp. iSi chose BiSoftMES because this software didn't have to be developed from scratch. It already contains numerous standards, templates and interfaces, which are usually used in

The use of BiSoftMES creates a digital twin that enables, so to speak, a virtual, data-based presentation of all production processes. This increased transparency in production has also led to increased traceability for iSI. Each individual container is now traceable, which on the one hand helps to process complaints more efficiently. Prior to this implementation, the employee had to obtain the necessary information at various points in the company. On the other hand, the use of BiSoftMES iSI now also allows access to detailed data on fault reasons, which allows manufacturing processes to be optimized based on this information.

“With BiSoftMES, we have successfully replaced our old MDE system and now have valid, up-to-date data on all production processes. They form the basis for greater transparency and traceability, which enables us to optimize our manufacturing processes and expand BiSoftMES to other production areas. Since we involved our employees early on, we were able to dispel reservations and achieved a high level of acceptance among the workforce for a quick and easy introduction of BiSoftMES. ”

Peter Travnicek, Development Engineer and MES Project Manager at iSi Group, Vienna


With 950 employees at production sites in Germany, Romania, England and the Czech Republic, the COHLINE group of companies manufactures pipe and hose line systems (Smart Fluid Systems) for all branches of industry that use media-carrying lines, for example for oil supply, cooling or hydraulics.

As part of a funding measure by the Federal Office of Economics and Export Control (BAFA) to modernize production in the vehicle manufacturer and supplier industry, COHLINE was looking for a manufacturing execution system that both meets the manufacturer's current requirements and can be flexibly expanded for future areas of application.

The family company chose BiSoftMES from gbo datacomp. MES acts like a data hub by collecting, processing, compacting and visualizing machine data from the systems.

The decision for BiSoftMes as part of the BAFA funding application was based in particular on its modularity. In other words, the system adapts to requirements and can grow accordingly.

By evaluating machine data, precise information is now available about forming times, forces acting during forming and cycle times. On this basis, COHLINE is able to optimize individual production steps in a targeted manner.

COHLINE has also digitized the test stations by using BiSoftMES. For example, the tightness of a ball head is checked down to the micrometer range by an extremely high-resolution camera. Eddy current measurement is used to detect cracks in the surface or within a pipe. The contour check ensures that the ball head is correctly shaped to fit the pump or connections later. With BiSoftMES, every tested line is traceable.

“The use of BiSoftMES enables us to meet the high quality and precision requirements, which are particularly required by the automotive industry. Thanks to the high level of transparency and traceability in manufacturing, we exploit optimization potential, develop product innovations and gradually put predictive maintenance into practice. Ultimately, digitization with BiSoftMES forms the basis for COHLINE to produce in a climate-neutral way from 2035. ”

Sascha Freymann, Head of Technical Workshop, COHLINE Group

Tips for choosing a suitable MES system

Selecting the right MES system is crucial for successful integration of your MES system. Here are some helpful tips to help you choose a suitable MES system:

  1. Define requirements: Before you start looking for a suitable MES system, you should define your requirements precisely. Consider which features and integrations your company needs to optimize your production processes.
  2. Industry-specific solutions: Some MES systems are specifically tailored to specific industries and production environments. Verify that the chosen system has experience and expertise in your industry to ensure that it meets your specific needs.
  3. scalability: Make sure that the selected MES system is scalable and can adapt to future growth and changes in your company. It should be able to grow with your business and meet new requirements.
  4. Ease of use: An intuitive and user-friendly MES system is important to ensure acceptance and effective use by your employees. Test the user interface and make sure that your employees can easily learn and use the software.
  5. Integration of MES software and data: The selected MES system should enable seamless integration of your existing software and data. Check whether the system is compatible with your existing systems and enables seamless data exchange.
  6. Security and privacy: Make sure that the MES system has implemented robust security measures to ensure that your corporate data is protected. Privacy policies and compliance should also be considered.
  7. References and reviews: Before choosing, get an idea of the vendor's reputation and reliability. Read customer reviews and search for reference customers to get first-hand information.

With these tips, you can ensure that you find a suitable manufacturing execution system that meets your system integration, software integration, and data integration requirements, and efficiently optimize your production.

MES system integration: success through optimized production

In this section, we summarize the benefits and successes of optimized production through the integration of the MES system. Through efficient process integration, you can increase your production output and achieve more efficient processes. The integration of the MES system gives you the opportunity to automate and optimize your work processes, which leads to increased efficiency and productivity.

With comprehensive MES automation, you can use existing resources more efficiently and reduce turnaround times. Process optimization enables seamless integration of all processes, from material supply to production and quality control. With an integrated manufacturing execution system, you can concentrate on the essentials: optimising your production.

With optimized production through the integration of the MES system, you can not only save costs, but also improve the quality of your products. More efficient process integration enables a faster response to changes and reduces errors and waste. As a result, you improve customer satisfaction and strengthen your competitiveness.


Integrating the MES system is a decisive step towards optimising your production and increasing your efficiency. With seamless MES integration, you can better coordinate your workflows and improve production performance. The integration of MES software and data enables you to precisely monitor and control your production processes.

The benefits of successful MES software integration are manifold. It enables better data transparency, optimizes production processes and enables more precise planning. By integrating the MES system, you can reduce costs and improve the quality of your products.

This conclusion shows that careful MES data integration is a key success factor. Invest in a suitable MES system that meets your needs and get expert support to ensure efficient integration. In this way, you can prepare your company for future developments and trends in the area of MES integration.


Why is the integration of the MES system important?

Integrating the MES system is important to increase your production output and optimize your processes. Efficient process integration allows you to seamlessly coordinate your manufacturing process and improve communication between production planning and control.

What is MES integration?

MES integration is the process of integrating a Manufacturing Execution System (MES) into your production environment. This involves seamlessly connecting various systems and data to enable seamless communication and coordination of production processes.

What are the advantages of an automated and process-integrated MES solution?

An automated and process-integrated MES solution offers a wide range of advantages. It provides improved transparency and control over your production processes, optimizes production efficiency and quality, and makes it easier to meet compliance requirements.

What are the benefits of MES integration?

MES integration offers numerous advantages. It enables seamless integration of your MES software and data, optimizes production processes, reduces errors and enables better use of resources. It also improves planning and enables real-time feedback for continuous process optimization.

How can I optimally integrate my Manufacturing Execution System into my production?

In order to optimally integrate your manufacturing execution system into your production, you should take a step-by-step approach. Start with a comprehensive analysis of your current processes, identify areas with optimization potential, and develop a clear integration strategy. Make sure that your MES system meets your specific requirements and implement it carefully, taking into account all relevant interfaces.

What challenges can arise when integrating the MES system?

When integrating the MES system, various challenges can arise. These include, for example, the complexity of the system landscape, technical interface problems, resistance to change and the need for clear communication and cooperation between the various departments.

Which best practices help with successful MES integration?

Successful MES integration includes proven best practices such as careful planning and preparation, clear communication, close collaboration between the teams involved, regular review and adjustment of the integration, and employee training. It is also important to draw on expert knowledge and rely on proven technologies and standards.

What role does MES software play in integration and process?

MES software plays a decisive role in the integration of the MES system. It serves as a central platform for collecting, analyzing and managing production data. Good MES software should offer a user-friendly interface, flexible customization options, and smooth integration with other systems.

Are there any case studies of successful MES integrations?

Yes, there are many case studies about successful MES integrations. These case studies show how companies have benefited from optimized process integration and were able to improve their production processes. They provide valuable insights and highlight best practices for successful MES integration.

What are tips for choosing a suitable MES system for integration?

When choosing a suitable MES system for integration, you should consider your specific requirements. Look for a user-friendly interface, scalability, flexibility, integration options, vendor experience, and customer support. A thorough evaluation and testing phase can help you find the right MES system for your integration.

What are the benefits of integrating the MES system for production?

The integration of the MES system offers numerous advantages for production. It enables improved planning, efficiency gains, cost and time savings, better use of resources, and an increase in product quality and customer satisfaction. By optimizing production, you can sustainably increase your company's success.

What is the conclusion about the integration of the MES system?

The integration of the MES system offers immense benefits for companies. It enables optimized production, improved process efficiency, better use of resources and an increase in product quality. Realizing these benefits requires careful planning, preparation, and implementation of the integration.

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