The verdict in three sentences
An MES (Manufacturing Execution System) bridges your ERP and the shop floor: it collects machine data in real time, computes OEE, traces batches and drives scrap down. A vendor MES deploys faster but adapts poorly to atypical lines; a custom build (70,000-180,000 EUR, 8-14 months) fits your machines, routings and indicators. The ROI shows in OEE: +5 to +15 points on a plant billing 8 M EUR of output means hundreds of thousands of euros of recovered capacity per year.
Vendor MES vs custom
Vendors (Siemens Opcenter, AVEVA, Rockwell) offer complete suites but heavy on licences and integration. Custom targets your real needs: PLC connection via OPC-UA/MQTT, OEE computed to your method, operator screens tailored to your stations.
| Criterion | Vendor MES | Custom MES |
|---|---|---|
| Initial licences | 40,000-120,000 EUR | 0 EUR |
| Development/integration cost | 60,000-200,000 EUR | 70,000-180,000 EUR |
| Annual maintenance | 18-22% of licences | 12-18% of build |
| Deployment timeline | 10-18 months | 8-14 months |
| Machine/IoT connection | Standard (drivers) | Custom OPC-UA / MQTT |
| Fit for atypical lines | Limited | Total |
| Code ownership | No | Yes (asset) |
ROI on scrap reduction and OEE
Assumption: 3-line plant, 8 M EUR/year output, initial scrap 6%, initial OEE 68%. 2026 ballpark.
| Lever | Before MES | After MES (year 2) | Annual gain |
|---|---|---|---|
| Scrap rate | 6.0% | 3.5% | ~200,000 EUR |
| OEE | 68% | 76% | +8 pts capacity |
| Recovered capacity | - | +12% | ~250,000 EUR |
| Manual data-entry time | 15 h/week | 3 h/week | ~22,000 EUR |
| MES cost (120,000 build + support) | - | ~140,000 EUR/year 1 | - |
By year 2, cumulative gains (scrap + capacity + data entry) exceed 470,000 EUR, against a steady-state cost of ownership around 30,000-40,000 EUR/year: the custom MES pays back in under 18 months.
Mini case study
Laurent, industrial director of a precision-machining SME in Berlin (85 staff, 3 CNC lines), loses 6% of output to scrap, i.e. ~480,000 EUR/year. Cutting scrap to 3.5% via real-time traceability and MES quality alerts saves ~200,000 EUR/year. His 120,000 EUR investment is covered by this line item alone in 8 months, before counting the +8 OEE points that free up the equivalent of a partial fourth line.
FAQ
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What does a custom MES cost in 2026?
Budget 70,000-180,000 EUR depending on line count, machine-connection complexity and scope (OEE, traceability, quality, scheduling). A single-line pilot can start around 55,000 EUR.
How does the MES connect to my machines?
Via industrial standards OPC-UA, MQTT or Modbus for recent PLCs, and through sensors/gateways for older machines. Each collection point is modelled to feed real-time OEE.
What OEE gain can I expect?
A well-deployed MES typically delivers +5 to +15 OEE points in 12-24 months by cutting micro-stops, scrap and poorly measured changeover times.
Should the MES integrate with the ERP?
Yes, that is the core of the value: the MES receives work orders from the ERP (SAP, Odoo) and returns actual quantities, scrap and times, eliminating double entry.
How long before first results?
Full deployment takes 8-14 months, but the first reliable OEE indicators appear 2-3 months after the first instrumented line goes live.
Let's scope your project. Give us your line count, your PLCs and target indicators (OEE, scrap, traceability), and we will cost a custom MES with scrap-reduction ROI. 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.
