The verdict in three sentences
A custom MES/scheduling system for a manufacturing SME runs between 45,000 and 120,000 EUR depending on the number of workstations, machine data capture and ERP integration. The payback is measured in OEE (+8 to +15 points), lower work-in-progress and the end of Excel re-keying. Below 30 workstations a standard package often suffices; beyond that, or with specific processes, custom pays back in 12 to 24 months.
What an MES covers and what it costs
Scope drives the budget. Here are the main functional blocks and their 2026 order of magnitude for custom development.
| Module | Scope | Indicative cost (EUR) | Lead time |
|---|---|---|---|
| Work orders | Creation, sequencing, statuses | 8,000 - 16,000 | 3-4 wks |
| Real-time shop-floor tracking | Station clock-in, tablets | 10,000 - 22,000 | 4-6 wks |
| Scheduling / load planning | Planning, bottlenecks, priorities | 12,000 - 28,000 | 5-8 wks |
| Lot & material traceability | Genealogy, product recall | 8,000 - 18,000 | 3-5 wks |
| Machine data capture (IoT/OPC-UA) | Counters, downtime, auto OEE | 10,000 - 30,000 | 4-8 wks |
| Non-conformities & quality | Scrap, rework, root cause | 6,000 - 14,000 | 2-4 wks |
| ERP integration (Sage, SAP B1) | Items, orders, stock, purchasing | 8,000 - 20,000 | 3-6 wks |
A focused 3-4 module project lands around 55,000-75,000 EUR; a full MES with machine data capture climbs toward 100,000-120,000 EUR.
The measured shop-floor impact
The real gain comes not from the software but from what it makes visible: micro-stops, poor quality, setup times. Order of magnitude observed at an SME of 40-60 staff.
| Metric | Before | After MES | Effect |
|---|---|---|---|
| Average OEE | 62 % | 74 % | +12 pts |
| Work-in-progress (days) | 9.5 | 6.2 | -35 % |
| Excel re-keying | 6 h/day | 0.5 h/day | -90 % |
| Scrap rate | 4.1 % | 2.4 % | -1.7 pt |
| Late deliveries | 14 % | 5 % | -9 pts |
| Lot inventory time | 2 days | 15 min | near real time |
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Mini case study
Antoine, operations director at a precision-machining SME in Dublin (48 staff, 8.5M EUR revenue). He invests 68,000 EUR in a custom MES: work orders, tablet-based shop-floor tracking, data capture on 6 CNC machines and Sage integration. His OEE rises from 63 to 73 % in eight months. On machine capacity valued at 1.9M EUR/year, +10 OEE points free roughly 190,000 EUR of capacity; capturing even half as additional revenue pays the project back in under nine months, before scrap and re-keying savings.
FAQ
Do we have to replace the existing ERP? No. The MES connects to the ERP (Sage, SAP B1, Dynamics) via API or database. The ERP keeps sales and accounting; the MES runs the shop floor. Integration is 8,000 to 20,000 EUR.
How long until go-live? Plan 4 to 8 months for a 3-4 module scope, starting with a pilot on one line. A big-bang rollout across the whole plant is discouraged.
Is machine data capture mandatory? No, but it is what makes OEE reliable. Without sensors, tracking stays declarative (operator clock-in), which is fine to start. You can add it in phase 2 for 10,000 to 30,000 EUR.
Isn't a standard package enough? Below 30 workstations with standard processes, yes (5,000-25,000 EUR/year subscription). Custom is justified by specific processes, strong regulatory traceability or a need for independence from licences.
How are operators trained? Simplified touch interfaces, a half-day of training per station, and a shop-floor champion. Adoption is the real risk: you handle it through design, not documentation.
Let's scope your project. Tell us about your plant (number of workstations, machines to connect, current ERP) and your indicative budget, and we'll frame the most profitable MES scope. 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.
