The verdict in three sentences
A custom MES (Manufacturing Execution System) costs EUR 70,000 to 180,000 in 2026 and ships in 7 to 12 months, machine connectivity included. The first gain comes from OEE (Overall Equipment Effectiveness): measuring it in real time reveals 10 to 25 % of hidden productivity in stoppages, micro-stops and non-quality. Custom is justified for atypical production processes that off-the-shelf MES can't model, but ERP integration remains unavoidable.
What an MES costs in 2026
an Amsterdam plant manager chooses between a vendor MES (fast, but rigid on specific processes) and custom (aligned, connected to the machines). Order of magnitude for 2026:
| Item | Vendor MES | Custom |
|---|---|---|
| License / initial dev | EUR 30,000 - 90,000 | EUR 70,000 - 180,000 |
| Recurring cost | 15 - 40 % license/yr | Hosting EUR 200 - 500/mo |
| Implementation time | 4 - 9 months | 7 - 12 months |
| Machine/PLC connectivity | Per connectors | Custom, unlimited |
| Atypical process modeling | Hard | Native |
| Maintenance | Included | 12 - 18 %/yr |
Machine connectivity (sensors, OPC-UA, PLC feed) often accounts for 15 to 30 % of the budget: price it precisely at discovery.
OEE, a mine of hidden productivity
OEE combines availability, performance and quality. Measuring it continuously turns gut feel into decisions. Typical 2026 impact:
| OEE component | Before measurement | After MES |
|---|---|---|
| Availability | 75 - 82 % | 85 - 92 % |
| Performance (rate) | 80 - 88 % | 90 - 95 % |
| Quality | 92 - 96 % | 96 - 99 % |
| Overall OEE | 55 - 68 % | 74 - 85 % |
| Declaration entry time | 30 - 60 min/shift | 5 - 10 min/shift |
| Batch traceability | Partial, paper | Full, digital |
Moving OEE from 62 % to 78 % on a line is +26 % capacity with no machine investment: often equivalent to one added line avoided.
Mini case study
Thomas runs a precision-machining subcontractor in Amsterdam: 3 lines, 45 operators, EUR 12M turnover. His estimated OEE hovers around 63 %, without reliable measurement. He invests EUR 135,000 in a custom MES (delivered in 10 months, PLC connectivity included) plus EUR 20,000/yr maintenance. Raising OEE to 77 % across the lines, he gains ~22 % capacity: on a saturated order book, that means about EUR 1.8M additional turnover absorbable without a new machine, with a contribution margin well above the project cost in the first full year.
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FAQ
Vendor MES or custom?
If your processes are standard, a vendor MES (EUR 30,000-90,000 + maintenance) suffices. For atypical lines or product families, or strong traceability specificity, custom (EUR 70,000-180,000) is justified.
Do machines need to be connected?
Yes, for reliable OEE. PLC feeds (OPC-UA, sensors) avoid manual entry and give real-time OEE. This item is 15 to 30 % of the budget.
Does the MES replace the ERP?
No, it complements it. The ERP handles purchasing, stock, accounting; the MES drives the shop floor. Two-way integration (work orders, declarations) is essential.
How long to deploy?
Allow 7 to 12 months, including a pilot phase on one line before rollout. Change management with operators is a key success factor.
What annual maintenance budget?
Maintenance of 12 to 18 % of dev cost, roughly EUR 8,000 to 32,000/yr. It covers evolutions, machine connectors and shop-floor support.
Let's scope your project. Tell us your number of lines, machine fleet and traceability/ERP needs, and we'll define scope, an indicative budget and a 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.
