The verdict in three sentences
A custom MES (Manufacturing Execution System) costs between 60,000 and 250,000 EUR (excl. VAT) in 2026 depending on the number of lines, machine connectivity and ERP integration. It controls production in real time: work order (WO) tracking, traceability, OEE and shop-floor reporting. The typical gain is +12 % OEE, paying back the investment in 12 to 24 months in a moderately automated plant.
MES modules and their cost
The MES bridges the ERP (which plans) and the shop floor (which produces). Each module is priced by the complexity of your processes and the number of collection points.
| Module | Key function | 2026 range (EUR excl. VAT) | Indicative time |
|---|---|---|---|
| WO tracking | Release, progress, declarations | 12,000 - 30,000 | 5-8 wks |
| Traceability | Batches, serial numbers, genealogy | 10,000 - 35,000 | 5-9 wks |
| Machine data capture | PLC connection, OPC-UA, IoT | 15,000 - 60,000 | 6-12 wks |
| OEE calculation | Availability, performance, quality | 8,000 - 22,000 | 4-7 wks |
| Quality management | Checks, non-conformities, SPC | 10,000 - 30,000 | 5-9 wks |
| ERP integration | SAP, Sage X3, WO/stock exchange | 12,000 - 40,000 | 6-10 wks |
ROI and expected OEE gain
The MES creates value by cutting downtime, scrap and manual entry. Here is a 2026 order of magnitude by plant size.
| Plant profile | Lines / stations | OEE before | OEE after (est.) | 2026 budget (EUR excl. VAT) | Payback |
|---|---|---|---|---|---|
| SME workshop | 2-4 stations | 62 % | 71 % | 60,000 - 90,000 | 18-24 mo |
| Mid-size site | 5-10 lines | 68 % | 78 % | 110,000 - 180,000 | 12-18 mo |
| Multi-site | > 10 lines | 70 % | 82 % | 200,000 - 250,000+ | 12-15 mo |
A 10-point OEE gain on a line producing 2M EUR/year of output represents about 200,000 EUR of recovered capacity, with no machine investment. Add lower scrap (often -15 to -25 %) and the end of paper re-entry. Annual maintenance: 15 to 20 % of the project cost.
Mini case study
Claire, plant manager of a plastics-processing SME in Lyon, runs 6 injection presses with paper tracking and OEE measured at 66 %. Untracked stoppages and late-detected scrap are costly. A custom MES at 140,000 EUR (excl. VAT) connects the 6 presses over OPC-UA, computes OEE in real time and triggers quality alerts. Within 9 months OEE rises to 76 %, i.e. +10 points on 4.5M EUR of production revenue: about 450,000 EUR of recovered capacity and 20 % less scrap. ROI reached in under 12 months.
FAQ
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Custom MES or off-the-shelf vendor solution?
A vendor solution (60,000 to 200,000 EUR licences + integration) suits standard processes. Custom is warranted when your routings, quality checks or machine connections are specific and become a competitive edge.
Can old machines be connected?
Yes, through gateways (IoT sensors, counting boxes, OPC-UA) even on equipment with no native interface. This batch is often 15 to 30 % of the budget.
How long to deploy?
Budget 6 to 12 months. A pilot on one line (WO tracking + OEE) can go live in 12 to 16 weeks before roll-out.
How does the MES connect to my ERP?
Via API or structured file exchange: the ERP sends planned WOs, the MES returns production declarations and stock consumption in real time.
What concrete traceability gain?
Product genealogy (batch, material, machine, operator) enables a targeted recall in minutes instead of days, a major asset in food, pharma or automotive.
Let's scope your project. Tell us your number of lines, your ERP and your OEE/traceability goals; we'll frame a scope with an indicative budget and a possible pilot. 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.
