As a consultant with nearly 30 years of experience in the Manufacturing Execution Systems (MES) market, I've implemented hundreds of solutions across Fortune 500 enterprises. Over the years, I've witnessed firsthand how the MES landscape has evolved, and a common question I often hear is: Is MES dead? We’ll answer that in a minute, but first, let’s talk about where MES came from and how we got here.
MES and the Purdue Model
Back in the 80s and 90s, the Purdue model (also known as the ISA-95 standard architecture) was the foundation for enterprise systems. It defined how data moved between the plant floor and enterprise systems, with a clear structure that helped connect operations to broader business goals.
As a production software solution, Manufacturing Execution Systems fit nicely into Level 3 of the model. MES solutions bridge the gap between Enterprise Resource Planning (ERP) and process control, tracking the manufacturing process from raw material to finished product. (By the way, if you need a refresher on MES, please check out our comprehensive blog on all things digital plant.)
So, as MES technology continues to advance, the Purdue model has shown its age.
Figure 1. ISA-95 model
Then and Now
Today’s manufacturing environment looks nothing like it did 20 years ago. The Purdue model reflects an era where enterprises operated in silos. Information sharing was limited and slow, frequently resulting in inefficiencies and gaps in information.
Sure, Levels 0, 1, and 2—where equipment, PLC sensors, and SCADA systems live—have remained largely unchanged. But the real transformation is happening above the shop floor. Driven by Smart Factory initiatives, the Industrial Internet of Things (IIoT), and Industry 4.0, organizations are integrating operational technology (OT) data from the shop floor with enterprise data at the business level (levels 3-4).
Rapid advancements in networking, software, and integration tools have led to digital solutions that can actually integrate all this operational data in a central, easily accessible hub. This unlocks new capabilities, like process optimization, predictive maintenance, and instant visibility into performance metrics.
Systems that were once separate are converging into a higher, unified layer of manufacturing intelligence.
Blurring the Boundaries: Level 3 & 4
One significant outcome of this that the line is getting blurry between Level 3 systems (such as Quality Management Systems (QMS), Laboratory Information Management Systems (LIMS), Manufacturing Execution Systems (MES), and Computerized Maintenance Management Systems (CMMS)) and Level 4 systems (like Enterprise Resource Planning (ERP), Manufacturing Resource Planning (MRP), and Product Lifecycle Management (PLM)).
In practical terms, traditional level 3 systems are now deeply integrated with levels 0, 1, and 2, making data from the shop floor instantly accessible. But more importantly, these systems are also connecting more seamlessly with level 4 systems through digital platforms, creating a unified flow of information across the enterprise.
A New Era for Data and Decision-Making
Technology has finally caught up to the promise of the Purdue model: getting actionable data to the right people in a way that’s easy to understand and act on.
Just as industrial machines have evolved from relay logic to PLCs and beyond, MES and other Level 3 systems have followed suit. Traditional barriers between IT and operational technology (OT) are being bridged by modern security protocols and new technologies. Level 3 and Level 4 systems are becoming more open, with APIs and accessible endpoints that enable seamless integrations. Siloed systems are being replaced by flexible, interconnected platforms.
The result? A shift from rigid hierarchy to real-time collaboration.
The new MES isn’t a standalone production tool. It’s a unified digital ecosystem where all systems—manufacturing, operational, and enterprise—can talk to each other in real time. That’s where concepts like a "unified namespace" or a "single source of truth" become more than buzzwords. They become critical infrastructure.
Today, decision-makers can access real-time operational data from all levels in the enterprise. And with that comes faster, more informed, data-driven decisions—leading to increased agility, better performance, and improved profitability.
So, Is MES Dead?
Not at all. MES isn’t dying, it’s expanding. It’s no longer about isolated execution—it’s about enabling insight and agility across the entire enterprise.
The concept of MES has evolved to include digital platforms and technology that allow businesses to operate more efficiently and make better decisions faster.
And really, it’s not about whether MES is dead, but how MES is adapting to help businesses stay competitive and thrive. The journey toward smart manufacturing and more integrated digital plants is well underway, and MES continues to play a key role in that evolution.
The Rise of the MOM Model
This shift has given rise to the Manufacturing Operations Management (MOM) model. Unlike the traditional Purdue model, which represented a hierarchical, pyramid-like structure, the MOM model presents a flatter approach to manufacturing management. The MOM model reflects the modern reality where systems are more integrated, and the focus is on seamless collaboration across all levels of the enterprise.
In the MOM model, the silos and hierarchies that once defined the Purdue model are intentionally removed, symbolizing a move toward a more interconnected and agile manufacturing environment. This new model aims to simplify and streamline data flow across the organization.
Identifying the "Source of Truth"
At the core of this new MOM model is the concept of the "source of truth." Each function or system within your enterprise has a master system that serves as the authoritative record for that particular function. Whether it's inventory, production, quality control, or maintenance, each system holds the "source of truth" for its domain.
The key is making that data accessible. Cloud computing, MQTT, APIs, and modern integration tools allow each system to share its data without dumping everything into one location. Data stays where it belongs—but it becomes usable across the enterprise.
You may have heard us talking about the concept of UNS (unified namespace) or UAF (unified analytics framework). These are the real-world structures that provide fast, stable and effective data governance throughout your organization.
.png?width=600&height=300&name=CTA-UNS-UAF-Whitepaper(2).png)
The Future: A More Connected, Agile Ecosystem
The silos are coming down. As manufacturing continues to evolve, companies that embrace a more integrated, agile system will be better positioned to compete.
The MOM model isn’t a replacement for MES. It’s the next step.
Organizations that adopt this model gain faster access to insights, improve decision-making, and create more responsive operations—exactly what’s needed in today’s fast-moving markets.
Figure 2. Manufacturing Operations Management (MOM) model
How to Become a Smart, Integrated Digital Plant
Executives often ask me: "Okay, I get it—things are changing, but how do I actually make this shift to an integrated digital enterprise?"
The answer to that question varies greatly from one enterprise to another. It depends on a range of factors, including your current tech, the skills of your shop floor teams, the state of your IT environment, and the critical pain points you're trying to address.
There is no one-size-fits-all solution. But here are a few core principles to guide the journey.
Step 1: Know It's a Journey, Not a Quick Fix
One of the first things I emphasize is that this transformation isn't something you can simply buy off the shelf. It’s not a single piece of software or a quick implementation. It’s a journey—a process of continuous improvement. And like any journey, it’s important to choose the right partners and take it one step at a time.
Step 2: Create a High-Level Strategy
The very first step is to create a high-level strategy—a roadmap to guide your efforts. This strategy will outline where you want to go and how you plan to get there. When implementing a software platform, UX research with the actual users and stakeholders is essential. Now, the "how" may evolve as you move forward, and that's okay. Flexibility is key. So, don’t be afraid to adjust your priorities as you go.
Step 3: Stay Agile and Embrace Iteration
The digital transformation journey should remain agile. This means breaking down your larger goals into smaller, manageable steps. Aim for short-term, 8-12 week initiatives that you can implement and evaluate quickly. These smaller projects allow you to experiment and assess what works. If something isn’t working, you can use real feedback to pivot and adapt—without losing too much time or resources. The key is to take small, calculated steps and, most importantly, win or lose fast.
Step 4: Focus on Quick, High-Impact Wins
Focus on adding real business value as quickly as possible. The faster you can implement core improvements, the faster you can begin seeing results. These wins build momentum and create buy-in from your team. Again, don’t be afraid of failures. Getting something with tangible value into the hands of your team will also give you a chance to get real-life user feedback. Use this as an opportunity to learn, adjust, and improve. Then focus on the next key win.
Do You Have What It Takes?
MES is far from dead. But transforming your organization into a smart, integrated digital plant is not quick or easy. It’s a journey that requires careful planning, agility, and ongoing adjustments. By following these steps, organizations can unlock real-time visibility, cross-functional collaboration, and enterprise-wide agility. Discover the true power of MES in your enterprise.
Comments