How Manufacturing Execution Systems Shed Their Legacy Limitations and Became Essential

MES software evolved from rigid, expensive platforms into flexible, cloud-based solutions that bridge business strategy with real-time production operations.

Amy Sudibyo

Dec. 29, 2025

4 min read

Key Highlights

Legacy MES software was often inflexible and vendor-dependent, requiring massive upfront investments and making upgrades difficult, but modern MES offers modular functionality with low-code options and cloud deployment.
IoT advances enable unprecedented data access, allowing manufacturers to apply MES to track material usage, schedule maintenance proactively, digitize workflows and correct quality issues before products fail specifications.
For success with modern MES software, start with one clear objective like cost reduction or quality improvement rather than trying to solve everything at once, working backwards from business problems to technology solutions.

Manufacturing execution systems (MES) developed a reputation for being too rigid, expensive and out of sync with modern manufacturing operations. But now, as supply chain issues, economic pressures and compliance requirement demands intensify, MES is making a strong comeback and shedding its cumbersome image.

With this in mind, it’s important to clarify MES, which is a broad term for a software platform to monitor and manage operations in a manufacturing environment. MES provides real time data and analytics of production processes, allowing for a strategic overview of operations that supports continuous improvement activities.

It’s different from other automation technologies such as SCADA and distributed control systems because MES does not perform any direct control of equipment. But in today’smanufacturing world, where the importance of real-time, data-driven decision-making has become clear, there’s growing recognition that MES is essential. It’s the tool that bridges the gap between big-picture business goals and day-to-day production realities.

Has MES really changed much?

Traditional MES options were inflexible and?vendor specific, often coming from the same major vendors of industrial automation hardware and software. Connectivity options were limited, making it difficult to get production data.

Legacy MES deployments were expensive and software limitations often meant that the entire functional model had to be designed at once, requiring manufacturers to commit to a large amount of functionality upfront. Expanding and upgrading systems was difficult and often also heavily dependent on vendor support.

In contrast, modern MES offerings more closely resemble IT software that operators are used to outside of manufacturing, with lightweight web clients, cloud deployment options, modular functionality and AI/ML features. This allows for integration with other business software platforms.

Modern MES more closely resemble IT software that operators have become used to outside of manufacturing, with lightweight web clients, cloud deployment options, modular functionality and AI/ML features.

In addition, modern MES software implementations can be rolled out in increments. The software is also much more flexible with low-code or no-code options, making it easier for your teams to make platform changes.

Adding to the potential for modern MES software is that operational technology has advanced substantially alongside advances in industrial networking brought by IoT technology, all of which make it easier to connect to plant floor equipment and gather production data.

As a result, modern MES has access to more data than ever before, with a greater capacity for contextualization of that data.

Here are a few examples of how manufacturing operations data can be used by MES to optimize productivity:

Variability in raw material costs is a huge issue in manufacturing. Use MES to track material usage in real-time and minimize waste.
Monitor equipment performance to better schedule planned maintenance activities, minimizing production downtime.
Digitize paper-based checklists and workflows to improve data availability and reduce the risk of human error.
Analyse quality data so processes can be corrected before products become out of specification.

Where to begin with MES today

The starting point is getting clarity on what you’re trying to achieve by implementing an MES.

Identify your major concern, such as cost, quality, schedule adherence, traceability or uptime. It is tempting to say all of these but the best results will be achieved by more clearly defining success and scope by picking one to two of these.

At Nukon, we help customers solve their business problems through the application of technology, not by implementing technology and then looking for problems to solve. We always recommend identifying the problems the business or users are facing and then working backwards towards the technology.

The bottom line is your MES journey doesn’t have to be complicated. Working with a digital advisory partner on a strategy-led approach makes transformation much more achievable.

Amy Sudibyo is a Technical Lead at Nukon, A Tetra Tech Company, and part of the SAGE Group. SAGE is a certified member of the Control System Integrators Association (CSIA). For more information about SAGE Group, visit its profile on the Industrial Automation Exchange.