The verdict in three sentences
A custom MES (Manufacturing Execution System) costs between 90,000 and 200,000 EUR in Frankfurt in 2026, tracking work orders, machines and quality in real time over 6 to 12 months. An off-the-shelf MES starts fast but imposes its model and bills licences and modules as you scale. Custom is justified when your processes (aerospace, food, precision engineering) demand truly specific traceability and OEE calculation.
What a custom MES costs in Frankfurt in 2026
Budget depends on the number of lines, the level of machine connectivity and quality requirements.
| Module | Scope | Indicative 2026 cost (EUR) |
|---|---|---|
| Work-order tracking & scheduling | Release, progress, disruptions | 18,000 - 40,000 |
| Machine data capture (IoT/OPC-UA) | Sensors, PLCs, real time | 20,000 - 45,000 |
| OEE calculation | Availability, performance, quality | 12,000 - 28,000 |
| Traceability & genealogy | Batches, components, batch record | 15,000 - 35,000 |
| Quality management & scrap | Controls, non-conformities, SPC | 12,000 - 30,000 |
| ERP/MRP integrations | API, BOM sync | 10,000 - 25,000 |
| Full project | All modules + acceptance | 90,000 - 200,000 |
Add TMA (maintenance) of 3,000 to 5,000 EUR/month for hosting, support, enhancements and keeping machine connectivity alive.
Custom or off-the-shelf MES: the comparison
Vendor licence costs climb with the number of seats and machine connections.
| Criterion | Off-the-shelf MES | Custom MES |
|---|---|---|
| Upfront cost | 40,000 - 120,000 EUR (licences + integration) | 90,000 - 200,000 EUR |
| Recurring annual cost | 15 - 25% of licences/year | 36,000 - 60,000 EUR (TMA) |
| Production model | Imposed | Yours |
| Heterogeneous machine connection | Often limited | Custom (OPC-UA, Modbus) |
| OEE calculation | Standard | Your exact definitions |
| Code ownership | Vendor | 100% yours |
Across a heterogeneous, ageing machine park, the ability to connect every asset often makes the difference: that is where off-the-shelf MES hits its limits.
Mini case study
Marc, industrial director of an engineering SME in Frankfurt (3 lines, 62% average OEE), produces 4.2M EUR/year of added value. Each OEE point gained is worth roughly 68,000 EUR/year of extra capacity.
His custom MES at 165,000 EUR lifts OEE from 62% to 73% (+11 points), i.e. 748,000 EUR/year of recovered capacity, of which he concretely monetises 40%, or 300,000 EUR/year. He also cuts scrap from 4.1% to 2.3%. With 54,000 EUR of annual TMA, the investment pays back in under 12 months, one of the fastest ROIs in industry.
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FAQ
Can we connect old machines with no interface?
Yes. You add sensors (counting, current, cycle) or OPC-UA/Modbus gateways. Budget 1,500 to 5,000 EUR per machine depending on age and protocol.
How long for a custom MES?
Expect 6 to 12 months depending on the number of lines and integrations. A work-order + OEE scope on a pilot line ships in 4 to 5 months.
Does the MES compute OEE with our definitions?
Yes, a major advantage of custom: availability, performance and quality are configured to your real rules, not a vendor standard.
Does the MES handle aerospace traceability?
Yes, with batch records, component genealogy and compliant archiving. This is a frequent case in Frankfurt that fully justifies going custom.
What OEE gain can we expect?
We commonly observe +8 to +15 points of OEE, each point worth tens of thousands of euros of capacity depending on your added value.
Let's scope your project. Tell us about your lines, machine park and traceability requirements for a precise estimate. 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.
