The verdict in three sentences
A custom MES (Manufacturing Execution System) is budgeted between EUR 80,000 and 200,000 depending on the number of lines, PLC connectivity and traceability depth. The timeline is 7 to 14 months with maintenance around EUR 1,200/month. ROI comes mainly from OEE: +5 to 10 points often outweighs the project cost within the first year.
What an MES covers and its price
An industrial MES links the shop floor to the information system: work orders, machine time, quality, material traceability. A 2026 order of magnitude for a Berlin machining or automotive site.
| Module | Scope | Indicative price (EUR) |
|---|---|---|
| Scheduling & work orders | Real-time tracking | 18,000 - 38,000 |
| PLC/IoT data capture | OPC-UA, sensors | 20,000 - 45,000 |
| OEE calculation | Real-time boards | 12,000 - 28,000 |
| Quality & non-conformities | Checks, SPC | 12,000 - 30,000 |
| Material/lot traceability | Product genealogy | 12,000 - 32,000 |
| Maintenance (light CMMS) | Preventive, alerts | 6,000 - 27,000 |
A realistic total ranges from EUR 80,000 to 200,000, plus hosting/edge (EUR 400-800/month) and EUR 1,200/month maintenance.
ROI through OEE: the deciding calculation
An MES pays off in OEE points regained. Here is the impact for a line producing EUR 6M of value per year.
| OEE gain | Capacity gained | Annual value (EUR) |
|---|---|---|
| +2 points | 2% | 120,000 |
| +5 points | 5% | 300,000 |
| +8 points | 8% | 480,000 |
| +10 points | 10% | 600,000 |
With an MES at EUR 150,000, a mere 3-point OEE gain (EUR 180,000/year) repays the project in under a year. Traceability also cuts recall and non-conformity costs.
Mini case study
Stefan, operations director of a precision-machining SME in Berlin (3 lines, EUR 18M of value produced), moves OEE from 62% to 69% after deploying an MES at EUR 165,000. +7 OEE points = about EUR 1.26M of capacity gained per year. Even after deducting EUR 14,400/year maintenance, ROI is reached in under 2 months of production.
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FAQ
Can the MES connect to our existing PLCs?
Yes, via OPC-UA, Modbus or IoT gateways. The data-capture module is priced between EUR 20,000 and 45,000 depending on machine count.
How long to deploy an MES?
Between 7 and 14 months. We start with a pilot line to validate PLC capture and OEE before rolling out.
Does it interface with our ERP?
Yes, the MES exchanges work orders, stock and declarations with SAP, Sage X3 or your ERP via API. This is a key scoping point.
What OEE gain can we expect?
As an order of magnitude, +5 to 10 points in the first year from real-time visibility and fewer micro-stops.
What does the EUR 1,200/month maintenance cover?
Priority shop-floor support, fixes, updates, PLC-capture supervision and small enhancements.
Let's scope your project. Give us the number of lines, your PLCs and priorities (OEE, traceability, quality) and we will frame a budget between EUR 80,000 and 200,000. 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.
