The verdict in three sentences
A custom MES links your work orders, machines and ERP to track OEE in real time instead of three days later in Excel. Budget 60,000 to 150,000 EUR (excl. VAT) of build over 18 to 30 weeks, with 25 to 40% going to PLC and ERP integration. The payback shows up as OEE points recovered and scrap avoided, often within 18 months.
Off-the-shelf MES vs custom: what you actually pay
A vendor MES (Aveva, Siemens Opcenter) charges licences and modules; custom builds an asset you own. 2026 orders of magnitude for an SME of 60 to 200 staff, one site, 10 to 30 machines.
| Criterion | Vendor MES | Custom MES |
|---|---|---|
| Initial implementation | 80,000 - 250,000 EUR | 60,000 - 150,000 EUR |
| Annual licences | 15,000 - 45,000 EUR/yr | 0 EUR (hosting only) |
| Fit to real routings | Limited config | Total, on your process |
| Time to first line piloted | 20 - 40 weeks | 12 - 18 weeks |
| Code ownership | No | Yes |
| Maintenance / changes | Vendor-dependent | 12 - 20% of build/yr |
Over 5 years a vendor MES at 30,000 EUR annual licence adds 150,000 EUR to the initial ticket: custom wins as soon as you need to match atypical routings.
The real hidden cost: PLC integration
Pulling machine data (counts, downtime, causes) means wiring PLCs and sensors. This is where projects derail when ignored.
| Machine source | Integration method | Cost per line (2026) |
|---|---|---|
| Recent PLC (OPC-UA) | Standard connector | 2,500 - 5,000 EUR |
| Legacy PLC (Modbus) | Gateway + mapping | 4,000 - 8,000 EUR |
| Machine with no output | IoT box + sensors | 6,000 - 12,000 EUR |
| Operator entry (tablet) | Shop-floor screen | 1,500 - 3,000 EUR |
| Scale / quality check | Serial link | 2,000 - 4,500 EUR |
For 15 mixed machines, budget 50,000 to 90,000 EUR for reliable data capture alone: it is the foundation of OEE.
The gains: where the MES pays for itself
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| Metric | Before (Excel/paper) | After MES | Effect |
|---|---|---|---|
| Average OEE | 62% | 70% | +8 points |
| Scrap rate | 4.0% | 3.2% | -20% |
| Reporting/entry time | 12 h/week | 2 h/week | -83% |
| Batch traceability | 2 - 3 days | Instant | Compliance |
| Late deliveries | 9% | 4% | -55% |
Mini case study
Marc, industrial director of a 120-staff plastics SME near Lyon, runs at 62% OEE across 18 presses. Each OEE point is worth about 28,000 EUR of annual capacity. Moving to 70% (+8 points) recovers the equivalent of 224,000 EUR/year of capacity without buying a machine. His custom MES costs 110,000 EUR (build) plus 18,000 EUR/year hosting and maintenance. Even converting only half the theoretical gain into real margin, the project is paid back in under 12 months, and he owns the tool.
FAQ
How long before the first line is piloted? Expect 12 to 18 weeks for a first instrumented workshop, then a machine-by-machine rollout. The initial scope should stay at one pilot line to validate quickly.
Do we have to replace the ERP? No. A good MES connects to your existing ERP (Sage, SAP, Divalto) via API or an intermediate database; the ERP keeps management, the MES drives the floor.
Is OEE really reliable in a custom build? Yes, provided machine sources are wired correctly. Reliability comes from PLC integration, not the software: that is why this line item is 25 to 40% of the budget.
What annual maintenance cost should we plan? Budget 12 to 20% of the build per year for maintenance and changes, i.e. 13,000 to 22,000 EUR/year on a 110,000 EUR project, hosting included.
Can we start with a single module? Yes: many begin with OEE capture and work orders, then add quality, traceability and maintenance in budgeted increments.
Let's scope your project. Tell us about your shop floor — number of machines, existing ERP, priority metric (OEE, scrap, traceability) and indicative budget — and we will frame the MVP scope. Detailed quote within 48 h. WhatsApp +221 77 596 93 33.
Mohamed Bah
Fondateur, Kolonell
Passionate about digital and entrepreneurship in Africa, Mohamed has been helping Sénégalese businesses with their digital transformation since 2020. Founder of Kolonell, he believes every SME deserves a professional and accessible online présence.
