Leveraging Model-Based Enterprise and MES for Superior Manufacturing Outcomes
Maintaining quality is non-negotiable in high-complexity manufacturing, especially in sectors like aerospace and defense (A&D). With stringent regulations and the potential for severe consequences from minor defects, the role of Manufacturing Execution Systems (MES) is critical. Surprisingly, however, not all MES solutions fully embed quality management into their systems, so buyers beware. In our experience working with A&D companies, this absence can create gaps that are easy to miss. This blog explores how embedding quality management within an MES platform can really make a difference in production processes and strengthen quality assurance.
Proactive Quality Control in Complex Manufacturing
In complex discrete manufacturing, even slight defects can lead to significant issues, including rework, delays, and increased costs. Regulatory requirements mandate a thorough quality approach starting from the production’s onset. Relying solely on post-activity inspections can no longer suffice.
A well-integrated MES that embeds quality management transforms manufacturers from a reactive to a proactive quality assurance stance. Incorporating control plans into production workflows along with real-time data validations reduces the possibility and impact of defects in later stages. We’ve seen how this shift supports continuous monitoring, strict adherence to standards, and early identification of non-conformance issues, driving operational efficiency.
Embedded Quality in MES
MES is a hub for managing production activities, including resource allocation, work-in-process tracking, and scheduling. An MES with integrated quality management automates checks at every stage, capturing real-time errors and minimizing defect risks. When production issues arise, these systems facilitate immediate root-cause analysis and corrective actions, allowing teams to address problems faster.
This structured approach not only cuts downtime but also enhances overall efficiency. Real-time data sharing is pivotal in swiftly resolving quality issues, ensuring traceability, and fostering a culture of continuous improvement. Real-time process control switches away from defect tracking to defect prevention.
Extending Quality Management Beyond the Factory
A&D manufacturers often depend on extensive supply chains, with external suppliers accounting for up to 70% of components used in final assemblies. Without extending quality and conformity management to these suppliers, the risk of defective components entering production rises.
Integrating MES with Supplier Quality Management (SQM) enables manufacturers to uphold the same high standards throughout their supply chains. It becomes a one-stop shop to track supplier performance, guide them through testing, and ensure that only compliant components leave their facility and enter production. Early identification of supplier-related issues further mitigates risks and enhances visibility across the supply chain.
Quality Assurance, MES, and the MBE
The Model-Based Enterprise (MBE) integrates digital model definitions into MES, creating continuity across the entire product lifecycle. This integration and automation minimizes errors caused by miscommunication among departments, ensuring all teams—from engineers to inspectors—operate with accurate and up-to-date information.
We’ve seen that the road to successfully implementing MBE typically requires getting nine key disciplines involved, from Design Engineering to Sustainment Operations. MES platforms that support MBE facilitate buy-in and connectivity across these areas, making the transition easier and driving ROI.
MES and MBE work together to enable design and process improvements based on real-time shop floor feedback. They inform daily production and contribute to long-term product development, ensuring compliance with specifications and reducing defects. Moreover, MBE accelerates new product introductions (NPI) by streamlining communication and reducing the risk of errors during initial runs.
The process starts by evaluating and grading programs and then choosing where to implement MBE based on potential ROI. At iBase-t, we’ve developed implementation guidelines to help, which we’ll cover in a future blog.
Continuous Quality Improvement
Embedding quality management into MES establishes a vital feedback loop for ongoing improvement. Manufacturers can identify recurring issues, analyze process capability trends, and make informed decisions to optimize processes by collecting and sharing real-time data.
Integrating MES with systems such as Product Lifecycle Management (PLM) and Enterprise Resource Planning (ERP) provides a comprehensive view across the organization. This visibility has made it easier for our clients to respond faster to production challenges and drive superior outcomes for manufacturers and customers.
Investing in Integrated Quality Solutions
In today’s competitive landscape, A&D manufacturers must embed quality into every aspect of their operations to remain competitive. MES platforms with integrated quality management offer the tools to achieve optimal outcomes at every production stage. A unified digital ecosystem helps get all areas of the organization on board, from Design Quality to Factory Automation, and dramatically streamlines the implementation of MBE. Manufacturers can create a closed-loop system that fosters continuous improvement by combining MES with MBE principles and SQM.
As manufacturing evolves, companies that invest in MES platforms with integrated quality will drive innovation, efficiency, and stronger outcomes. At iBase-t, we’ve seen firsthand how our Solumina platform supports these goals. If you’re ready to take the next step, Solumina brings production, quality assurance, supply chain management, and sustainment together in one system. Tailored to complex discrete manufacturing, it’s designed to streamline operations and elevate your quality performance—and we’re here to guide you through it.
