Modern Factories

Let’s face it: Implementing Manufacturing Execution Systems (MES) is a bit like juggling flaming torches while riding a unicycle. It’s tricky, it’s fast-paced, and the stakes are high. But if done right, MES can transform your plant from chaotic data overload to a streamlined, real-time decision-making powerhouse. MES is no longer just a data collector — it’s the central nervous system of a modern digital factory. It’s what turns machine signals into actionable insights that can boost efficiency, improve quality control, and help plant managers sleep at night knowing everything is under control. In this article, I’ll walk you through the key dos and don’ts of implementing MES in your plant, with real-world examples and industry-specific insights.

Gangadhar Krishnamoorthy

Production planning in a plastic pipe and fittings plant spans continuous extrusion (for pipes) and batch-based injection molding (for fittings), but the real complexity lies beyond simply sequencing machines. Extrusion lines run continuously and must account for socketing operations, cooling cycles, and downstream dispatch readiness, while injection presses juggle mold changes, regrind usage rules, and order coupling requirements to ensure pipes and fittings stay aligned for assembly and shipment. Because tooling, semi-finished buffers, rework loops, and customer-specific dispatch constraints are deeply interlinked, schedulers must plan machines, tooling, material flow, and governance rules as one unified system. These overlapping constraints make PPS in pipes and fittings far more challenging than standard discrete manufacturing—and extremely sensitive to how well the planning system models real shop-floor logic.

Swapnil Thakre