When MES and ERP do not speak the same language

Why integrations often go wrong

One of the things we often experience with our pharma clients is issues with integration between MES and ERP. Although it should be quite simple to get the two systems to communicate, we often see that it quickly becomes very complicated. It typically has to do with the fact that the MES and ERP systems are each designed for different purposes, and therefore they do not naturally speak the same language. When data needs to be sent between the systems, errors or misunderstandings often occur because data mapping is not defined clearly enough.

Data mapping is simply the translation of data between systems. MES typically focuses on production processes, precision, and detailed process data. ERP, on the other hand, is a financial and logistical system that works with high-level data and production management. When data is sent between the two, it must therefore be "translated" very precisely. If this translation is not done correctly, important information can either be lost, misunderstood, or end up as completely useless data in the other system.

Consequences of poor real-time integration

Another challenge with MES and ERP integrations is real-time communication. In the pharma industry, time is not just money; it is also crucial for patient safety and quality assurance. Real-time means that data must be able to flow between MES and ERP without delays. Even a small delay of a few minutes can mean that production comes to a halt, or that quality controls are significantly delayed.

If the ERP system, for example, does not receive a notification from MES that a batch has been completed, the ERP system cannot initiate the next steps in the supply chain. This means that raw materials may not be delivered on time, inventory becomes inaccurate, and deliveries to customers are delayed. Ultimately, such problems can lead to lost orders, increased costs, and dissatisfied customers.

How to avoid typical pitfalls

To avoid problems with MES and ERP integration, it is crucial to focus on data mapping right from the planning phase of the project. This means that it is necessary to clearly and in detail define which data should be exchanged between the systems and exactly how this data is translated. Good data mapping requires not only technical skills but also insight into the practical needs in production.

At the same time, it is essential that real-time validation of data becomes an integral part of the solution. Real-time validation means that the systems continually and automatically check that the data being exchanged is correct, consistent, and complete before proceeding. If the data is incorrect, it must be corrected immediately, not only when issues arise further along the value chain.

Finally, the integration between MES and ERP should not be seen as a one-time task, but rather as an ongoing project that requires constant maintenance, regular testing, and continuous adjustments. The integrations should be evaluated regularly to ensure that they still meet the company's needs and technical requirements. By maintaining a continuous focus on the integrations, one ensures that the systems continuously work optimally together.

If you want to know more about how to best handle integration between MES and ERP in pharma, feel free to reach out to us so we can have an informal discussion.