Migrate to a modern MES to achieve leading edge capabilities

Systems controlling plant floor operations are changing rapidly to enable the smart factories of the future. Many manufacturers must now choose to invest in their current MES or migrate to a modern MES that will deliver the flexibility to adapt to changes in demand and keep pace with constantly changing requirements.

Modern MES goes beyond the boundaries of manufacturing areas to accommodate new manufacturing models, the integration of business related processes such as maintenance, quality and engineering, with the ability to expand into the entire supply chain. The risk of maintaining outdated legacy MES is higher than the risk of changing to a new MES.

Why replace MES

An MES needs to allow a company to evolve, grow and innovate. Legacy MES systems that have been severely customized over time make upgrades, integration, backwards compatibility, and future-proofing much more difficult. A system that has highly flexible configuration and allows for extension of core functionality is needed.

The reasons to switch range from supporting digital transformation initiatives and meeting customer needs to accommodate new technologies in production and products.

  • Ability to compete
  • Agility to respond
  • Resilience to move into the future
  • Ability to leverage new technologies

How to migrate to new MES

There is no single approach to migrating from a legacy MES to a new one and the strategy is driven primarily by three factors that must be weighted depending on the levels of interdependence, automation and downtime impact.


How much risk and risk exposure is associated.


How much time the project takes from start-to-finish, including the pre-migration, migration and post-migration phases.


How much costs are involved in the planning and execution of the selected strategy, including opportunity costs (e.g.: downtime).

Each migration case is unique

The environment and context conditions will determine the appropriate migration strategy, taking into consideration the risk, time and cost/effort.

Strategy with highest risk, but the shortest migration time and lowest cost

Paper or excel based MES
Stand alone MES Application

Balanced migration strategy

Integrated MES application, low automation

Strategy with the lowest risk, but the highest cost

Integrated MES application, high automation

Select the optimal migration approach

You may also be interested in...

Guide to successful MES replacement
White Paper
Guide to Successful MES Replacement

Migration strategies explained

Data coming out the machine and floating through the shopfloor
IoT Data Platform

Critical Manufacturing introduces the first combined MES and IoT Data Platform

case study_SMART-Software Project Enriches Controls and Culture - Preview
Case Study
Software Project Enriches Controls and Culture

Modern MES for memory IC back-end: SMART Modular Technologies

Accelerate progress towards Industry 4.0

Get Started