The verdict in three sentences
A custom MES (Manufacturing Execution System) costs between EUR 60,000 and EUR 160,000 in 2026 depending on the number of lines, connected machines and quality-tracking depth. The timeline runs 5 to 9 months including ERP and machine integration, followed by EUR 800 to 1,800/month of maintenance. The lever is not the software but OEE (Overall Equipment Effectiveness): +10 to 15 points and a scrap drop that repay the project in 12 to 24 months.
What a custom MES covers
An MES runs the shop floor in real time: work-order (WO) declaration, operator time capture, machine monitoring, inline quality control, material traceability and OEE calculation. Unlike an ERP that handles admin, the MES lives at the foot of the machines.
| Module | Function | Indicative 2026 budget (EUR) |
|---|---|---|
| WO tracking & scheduling | Release, prioritisation, live progress | 12,000 - 30,000 |
| Time & operator capture | Shop-floor clocking, badges, tablets | 8,000 - 18,000 |
| Quality control | Control plans, non-conformities, SPC | 10,000 - 26,000 |
| Machine / IoT monitoring | PLC feeds, counters, downtime | 12,000 - 35,000 |
| Material/lot traceability | Genealogy, lot numbers, recalls | 8,000 - 22,000 |
| OEE dashboard | Live KPIs, alerts, reporting | 6,000 - 16,000 |
| ERP integration | SAP, Sage, WO/stock exchanges | 10,000 - 28,000 |
Three-year total cost and hosting
The purchase price isn't the whole story: you must budget shop-floor hardware (ruggedised terminals, network), hosting and evolutive maintenance.
| Item | Year 1 | Year 2 | Year 3 |
|---|---|---|---|
| MES development | 60,000 - 160,000 | - | - |
| Shop-floor terminals (4-8) | 6,000 - 14,000 | - | 2,000 |
| Hosting / infra | 3,600 - 8,400 | 3,600 - 8,400 | 3,600 - 8,400 |
| Maintenance & evolutions | 9,600 - 21,600 | 9,600 - 21,600 | 9,600 - 21,600 |
| Cumulative total (low) | 79,200 | 92,400 | 107,200 |
| Cumulative total (high) | 204,000 | 234,000 | 266,000 |
An off-the-shelf MES SaaS is possible at EUR 30-80/seat/month, but hits a wall on specific processes: the custom build is what captures the +10-15 OEE points.
Mini case study
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Stefan, operations director of a precision-machining SME near Berlin (65 staff, 6 CNC machines), still runs on spreadsheets. His OEE is 62%. He invests EUR 98,000 in a custom MES over 7 months, plus EUR 1,200/month maintenance.
Raising OEE to 74% (+12 points) yields the equivalent of 0.7 machine of capacity without buying hardware, roughly EUR 185,000 of extra output per year at an 18% margin, i.e. EUR 33,300 of margin/year. Add the scrap drop (from 4.2% to 2.1%, ~EUR 22,000/year saved). The project pays back in about 18 months.
FAQ
What does a custom MES really cost in Berlin in 2026? Budget EUR 60,000 to 160,000 depending on lines and connected machines. A 2-line WO + quality scope without IoT lands around EUR 70,000.
What's the go-live timeline? Between 5 and 9 months, with 4 to 6 weeks just for ERP integration and PLC connection. A single-line pilot can start in 3 months.
Do machines need IoT from day one? No. Many start with manual tablet capture (EUR 8,000-18,000) then add PLC feeds (EUR 12,000-35,000) in phase 2 once ROI is proven.
What maintenance budget should I plan? Maintenance runs EUR 800 to 1,800/month depending on modules and SLA, plus EUR 3,600-8,400/year for hosting and infrastructure.
What OEE gain can I expect? A realistic gain is +10 to 15 points in year one, mainly from cutting undeclared downtime and scrap. It's the metric that funds the project.
Let's scope your project. Share your number of lines, machines to connect and current ERP, and we'll frame an MES to your target OEE. 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.
