The verdict in three sentences
A custom MES (Manufacturing Execution System) links your work orders, machine status and quality control on a single shop-floor screen, where a generic ERP stops at the order. Budget 50,000 to 140,000 EUR in Berlin in 2026 and a 5-to-9-month timeline depending on the number of connected lines and stations. The return on investment almost always comes from two measurable levers: OEE (Overall Equipment Effectiveness) gained and scrap reduced.
What a custom MES covers and what it replaces
Most industrial SMEs still run the shop floor with Excel, an accounting ERP and whiteboards. The MES consolidates real-time tracking: work-order declaration at the station, machine data capture, qualified downtime, material traceability and built-in quality control. The goal is not to rebuild everything but to connect what exists (ERP, automation, PLCs) without re-keying.
| Function | Generic ERP | Custom MES 2026 |
|---|---|---|
| Real-time work orders | Partial / manual | Native at station |
| Machine data (OEE) | Absent | PLC or IoT |
| Lot/serial traceability | Limited | Full, exportable |
| Shop-floor quality check | Optional module | Integrated in flow |
| Downtime management | Not qualified | Causes + Pareto |
| Rollout time | 3-6 months | 5-9 months |
What it really costs in Berlin in 2026
The budget depends mostly on the number of instrumented lines and the level of PLC integration. Here is a 2026 order of magnitude for the Berlin area.
| Scope | Lines / stations | Budget EUR | Timeline |
|---|---|---|---|
| 1-line pilot | 1 line, 3-5 stations | 50,000 - 70,000 | 5 months |
| Full shop | 2-4 lines | 80,000 - 110,000 | 6-8 months |
| Multi-shop | 5+ lines, 2 sites | 120,000 - 140,000 | 8-9 months |
| PLC connection | per line | 6,000 - 12,000 | included |
| Annual maintenance | - | 12-18 % of project | recurring |
Mini case study
Thomas, operations director of a precision-machining SME in Berlin, runs 3 lines with an average OEE of 68 %. He invests 95,000 EUR in a custom MES. By qualifying downtime and cutting micro-stops, he gains 4 OEE points on output valued at 2.2M EUR/year: roughly 88,000 EUR of recovered capacity per year. In parallel, scrap drops from 3.1 % to 2.2 %, saving 20,000 EUR. Payback reached in about 13 months, excluding maintenance.
FAQ
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Do we need to replace our ERP to install an MES?
No. The MES connects to the ERP via API or connector. In 80 % of 2026 projects the ERP stays in place and the MES handles shop-floor real time.
How long before we see an OEE gain?
The first reliable data arrives within 4 to 6 weeks of go-live. A 2-to-5-point OEE gain is realistic over the first 6 months depending on initial maturity.
Can we start with a single line?
Yes, and it is recommended. A 50,000-70,000 EUR pilot validates the architecture and the ROI before extending to the rest of the shop.
Does the software work without a stable internet connection?
Yes. An architecture with local capture and deferred sync guarantees continuity even during a network outage on the shop floor.
Who enters data at the station?
The operator, via a tablet or rugged touchscreen, in seconds. Machine data capture (PLC, IoT) automates the rest without manual entry.
Let's scope your project. Tell us your number of lines, your current ERP and your target OEE, and we will price your custom MES (scope, budget, timeline). 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.
