The verdict in three sentences
A production management system (MES/ERP) drives scheduling, inventory and traceability to turn an opaque shop floor into a measurable factory. In Berlin in 2026, custom costs 80,000 to 250,000 EUR excl. tax, a vendor ERP 60,000 to 200,000 EUR (license + integration), with 15 to 20 %/year maintenance. The real decider is a 5 to 10 point OEE gain, which is often worth more than the upfront price gap.
Custom vs standard ERP: the 5-year TCO
The purchase price isn't the whole story. Over five years, maintenance, licenses and customization reshuffle the deck.
| Item (5 years) | Custom MES/ERP | Standard vendor ERP |
|---|---|---|
| Build / initial license | 80,000 - 250,000 EUR | 60,000 - 200,000 EUR |
| Integration & configuration | Included | 30,000 - 90,000 EUR |
| Annual licenses (x5) | 0 EUR | 40,000 - 120,000 EUR |
| Maintenance / support (x5) | 60,000 - 150,000 EUR | 30,000 - 75,000 EUR |
| Business customization | Total | Limited, expensive |
| 5-year TCO (order of magnitude) | 140,000 - 400,000 EUR | 160,000 - 485,000 EUR |
For an atypical process (make-to-order, fine traceability), custom avoids the costly workarounds of a standard ERP. For a classic process, a vendor ERP stays relevant.
MES modules and what they deliver
An MES connects the shop floor to management. Each module attacks a specific source of loss.
| Module | What it solves | Range 2026 (EUR excl. tax) |
|---|---|---|
| Scheduling & shop-floor planning | Cuts machine idle time | 20,000 - 45,000 |
| Real-time production tracking | Measures OEE live | 18,000 - 40,000 |
| Inventory & materials | Prevents stock-outs and overstock | 15,000 - 35,000 |
| Traceability & batches | Targeted recalls, compliance | 18,000 - 40,000 |
| Quality control & non-conformities | Cuts scrap rate | 12,000 - 30,000 |
| Preventive maintenance | Reduces unplanned downtime | 12,000 - 28,000 |
A full MES ships in 8 to 14 months, going live shop by shop to limit risk.
Productivity ROI: what 5 to 10 OEE points are worth
OEE (Overall Equipment Effectiveness) measures availability, performance and quality. Every point gained converts directly into production capacity.
| Indicator | Before MES | After MES (+8 OEE pts) | Gain |
|---|---|---|---|
| Average OEE | 62 % | 70 % | +8 pts |
| Annual output | 100,000 parts | 112,900 parts | +12,900 parts |
| Value added (18 EUR/part) | 232,200 EUR | ||
| Scrap rate | 4.2 % | 2.8 % | -1.4 pt |
| Material & rework saving | 45,000 EUR | ||
| Total annual gain | ~277,000 EUR |
An annual gain near 277,000 EUR pays back a 150,000 EUR custom project in under seven months of production.
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Mini case study
Claire is CFO of a 90-employee industrial SME in Berlin specialized in metal parts. Her OEE tops out at 63 % and her scrap rate hits 4 %. She invests 160,000 EUR excl. tax in a custom MES covering scheduling, real-time tracking and traceability. Within a year, OEE climbs to 71 % (+8 pts), i.e. 13,000 extra parts at 17 EUR value added, plus 42,000 EUR of avoided scrap. Total gain: 263,000 EUR, project paid back in 7.3 months, excluding maintenance.
FAQ
Custom or vendor ERP for an industrial SME?
If your process is standard, a vendor ERP (60,000-200,000 EUR) is enough. If you make-to-order or need fine traceability, custom (80,000-250,000 EUR) avoids costly workarounds and follows your exact process.
What's the true 5-year cost?
Between 140,000 and 400,000 EUR for custom, 160,000 to 485,000 EUR for a vendor ERP with licenses and integration. Annual licenses weigh heavily over time.
How long to deploy an MES?
8 to 14 months, going live shop by shop. Start with scheduling and real-time tracking, then quality and maintenance.
What is OEE and why that number?
OEE measures availability x performance x quality. Moving from 62 to 70 % adds roughly 13 % capacity with no new machine: it's the main ROI lever of an MES.
Can the MES connect to the existing accounting ERP?
Yes, via API or connectors. The MES drives the shop floor and pushes production, inventory and cost data to your financial ERP without double entry.
Let's scope your project. Tell us your process (production type, number of shops, current OEE) and target budget: we cost build, integration and 5-year maintenance. 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.
