At local factories in Thailand, issues unique to the production site—such as production delays, inefficiencies from paper-based management, and quality inconsistencies due to reliance on individual workers—occur on a daily basis.
The key to solving these problems lies in the implementation of MES (Manufacturing Execution System).
In this article, we will clearly explain the challenges of production sites in Thailand, the benefits of MES implementation, the step-by-step introduction process, and key points for success.
Organize production site issues that are occurring at local factories
Let’s start by outlining the challenges occurring on the production floor at local factories.
Production does not proceed as planned, causing delays
Due to the lack of visibility into on-site progress, discrepancies between production plans and actual performance are often noticed too late. As a result, issues such as delivery delays, excess inventory, or parts shortages frequently occur.
Paper-based reports and Excel management are difficult to handle
Managing production instructions and records on paper or in Excel often leads to entry errors and delays in information sharing. Data aggregation also takes time, making it difficult to grasp the situation on site or make quick decisions.
Work depends on individual expertise, leading to quality and training inconsistencies
Work procedures and know-how often depend on the experience of on-site leaders, and training of new employees is left to individuals without standardization. This reliance on personal methods tends to result in fluctuations in production quality and efficiency.
Benefits of MES (Manufacturing Execution System) Implementation
Here, we will explain the improvements achieved through the implementation of MES.
Real-time visualization of production status
MES enables real-time monitoring of the progress of each line and machine operation status. Issues and delays that occur on site can be detected immediately, allowing for quick response and smooth sharing of information across departments.
Improved efficiency and accuracy through digitalization of paperwork
Work instructions and performance input can be done via terminals, and records are automatically aggregated. This reduces duplicate entries and transcription errors, easing the burden of clerical tasks on-site. Centralized data allows instant analysis of production volumes and quality data, contributing to the reduction of wasteful processes.
Standardized operation eliminates dependence on individual employees
With unified work instructions and inspection standards on MES, a work environment where everyone follows the same procedures is established. Training of new employees is also systemized, reducing dependence on specific individuals. This leads to reduced quality variation and continuous on-site improvement.
Steps to Implement MES (From Site Survey to Full Adoption)
Now, let’s look at the steps for MES implementation, from site survey to full adoption.
Identify on-site issues (site survey)
Observe the production floor at the Thai factory and list issues such as causes of delays and inefficiencies. Through interviews with local staff, we investigate root causes and clarify potential problems that may not be visible to the Japanese headquarters.
Consider solutions and design the system
For the extracted issues, determine which MES features and mechanisms should be applied. A system implementation plan is devised in a way that fits the local workflows. During the design stage, we also formulate policies for alignment with existing production management methods and integration with other systems (e.g., ERP) and equipment.
Pilot implementation and full-scale rollout
Instead of full implementation at once, MES is first introduced on a specific line or process. Operators receive training, and practical issues are identified. After resolving these issues, the implementation scope is gradually expanded to the entire factory. A phased rollout prevents disruption at the site.
Operational adoption and continuous improvement
Post-implementation, regular follow-ups are conducted until the system is fully adopted on-site. We re-train staff unfamiliar with the system and collect feedback from the field. Even after adoption, we support the creation of a continuous improvement cycle using accumulated MES data to enhance productivity and quality.
Strengths of TOMAS TECH’s Support (Total MES Implementation Support)
Now, let’s introduce the strengths of TOMAS TECH’s support from the perspective of total MES implementation assistance.
On-site survey and requirements definition
Bilingual consultants familiar with manufacturing floors conduct factory diagnostics. Taking into account Thai-specific culture and practices, we gather on-site feedback to organize issues and requirements. We bridge the gap between the Japanese headquarter and the local site to identify truly necessary improvement themes.
System design and proposal
Utilizing our extensive experience in manufacturing DX, we support the design of MES systems that are user-friendly and site-driven. We propose optimal solutions, including step-by-step implementation plans and designs for integration with other systems.
Implementation support (on-site deployment assistance)
We accompany your implementation project locally, supporting progress management and issue resolution. With multilingual training, we smoothly educate Thai operators. If issues arise, we respond promptly to ensure operations begin as planned.
Adoption support (operational follow-up)
Even after going live, we continue follow-up from the perspective of the production floor. In addition to confirming the adoption status and providing further instruction, we propose additional improvements based on collected data. Our end-to-end support ensures that even first-time MES implementations can be carried out with confidence.
Frequently Asked Questions About MES Implementation
Here we answer some common questions when considering MES implementation.
Q: Can MES be introduced even if on-site IT skills are limited?
A: Yes, it’s possible. By choosing MES with a simple and intuitive interface and introducing functions gradually, even sites with low IT literacy can manage. With educational support from the implementation partner, operations can be adopted without requiring specialized knowledge.
Q: Can MES be integrated with existing systems or equipment?
A: Yes, it can. MES can be integrated with other core systems (such as production planning systems and ERPs) as well as sensors and IoT devices on machines. It enables importing existing data or feeding back production results to other systems, allowing you to leverage current operations while gradually advancing your DX initiatives.
Q: How much does it cost to implement?
A: Costs vary depending on the scope of the project and system size. If using off-the-shelf MES software, you can adopt a subscription model with low initial costs. If customization is needed to suit your specific needs, development fees will apply. At TOMAS TECH, we begin with a consultation and propose the optimal plan to fit your budget, so you can proceed with peace of mind.
Conclusion: A “Step-by-Step Approach” Is the Key to Successful MES Implementation in Thailand
Challenges faced in Thai manufacturing sites such as “production delays,” “paper-based inefficiencies,” and “individual-dependent operations” can be steadily resolved through a phased approach with the right steps.Instead of aiming for perfection from the beginning, it’s important to start systemization little by little where you can. Improvements that are closely aligned with the shop floor can lead to significant outcomes, such as increased productivity and stabilized quality.
Even if you’re unsure about MES implementation in Thailand, you can confidently move your project forward by partnering with an experienced support provider.
TOMAS TECH provides comprehensive support for the DX transformation of your manufacturing operations through local expertise. Please feel free to contact us.
