Offering Summary
At Mescon, our engineers, have implemented several MES Solutions, some custom, others vendor solutions. These vendor solutions include:
- Citect Historian and Clients
- Dream Report
- GE Proficy (Plant Apps, RTIP)
- Microsoft MSSQL inc SSRS and .NET
- OSIsoft’s PI (OSI PI) and Clients
- Parsec’s TrakSYS
- Rockwell’s FTTM (formally RSSQL)
- Rockwell’s RSBizware (Obsolete)
- Rockwell’s Vantage Point
- Wonderware Historian and Clients
Other competitive solutions on the market we have had some exposure to, or attended training on, include:
- Crystal Reports
- CrystalReportsFactory MES
- Factory Industrial Historian
- Ignition MES (by SepaSoft)
- OFS
- Opera MES
- Rockwell Production Centre
- Siemens Simatic IT
- Thingworx (PTC)
Each system has its own pros and cons. Each of them typically uses MSSQL in some 
way, typically as the heart of the system. Some use MSSQL as the only data repository, storing both the configuration and data within MSSQL. In contrast, others use special data repositories, which can be an advantage for time series data analysis. However, storage will affect performance time, and users these days expect results in a few seconds.
With over 100 MES products on the market (see this MES list), it can be hard for you to choose which is the right solution! Software connect have reviewed a lot of the offerings.
Selection
It comes down to what is the best fit for you. This decision includes several factors, one of which is long term objectives. We have found that most people do not understand the practical possibilities, hence what they reasonably want. The current hype has allowed people to dream, but most scenarios are either already readily available or not reasonable. We have never known a well-implemented MES solution not to return a positive ROI within a few months. The return has transpired in a way we could not have perceived beforehand. Some would refer to this as a BFO (Blinding Flash of the Obvious).
Other factors to consider when choosing a solution include:
- Existing onsite equipment, software and infrastructure
- Existing vendor relationships
- Available expertise
- Ongoing support
- The amount and type of data to be collected
- The level of integration with other systems
- Response time for reports
- User-friendliness of interface
- Computing resources required
- Product maturity and adaptability
- Software capabilities and flexibility
Many will argue that cost is significant; we would say unknown 
costs are significant, particularly when the chosen solution does not deliver on the promises. However, when a project is successful, any cost is quickly recovered. It is about the return on investment.
We have found that most solutions will achieve what you want, but that each vendor product requires a level of configuration and customisation to get the desired outcome. A figure often quoted for services needed (configuration and customisation) after paying for the licences is 3:1. That is, the licence is only a quarter of the price. Do not expect any vendor product to be an out-of-the-box solution for you, although some are closer than others.
The installation of each solution typically involves the following stages:
- Installation of the software into a specially crafted server(s)
- Connection to the database server
- Client installation
- Creation of the factory digital twin (Plant Model)
- Setting up communication with the control (often an OPC server)
- Implementation of data transfer to and from the ERP
- GUI configuration
- Customisation
Product Summary
What follows is a quick summary of each of the products we know beyond the sales talk. The list is in alphabetical order. Please talk to us further if you want to know more. Unfortunately, the comparison cannot be summed up in a few paragraphs.
Crystal Reports, for a long time, was the add-on reporting package for various SCADAs and historians. With a change in licencing, it was dropped by many. It is still a good reporting package, but not as popular as it used to be and not a common choice, typically for commercial reasons.
Dream Report connects with most SCADAs and historians and produces reports in various styles and delivery methods. It is a very flexible package and has more capability than Microsoft’s reporting services. As it is only a reporting platform, you need an alternative method to send data to the plant. Several vendors have partnered with OceanData to include it in their offerings.
FTTM is super light and great for event data. It simply sits there and responds to triggers and passes and collects the data. It is not a good time-series historian, nor does it have GUI. Any interface needs to be developed using other tools. Theoretically, it is an ideal MES solution, as an MES solution should not need a user interface; other systems (Enterprise and Control) already exist to interface with the users. Typically, interface design is required to handle shortcomings in the control or enterprise systems.
GE Proficy Plant Applications is a stable product that has been around for a long time and was originally developed for discrete manufacturers. Unfortunately, it is heavy on computing resources and relies on a messaging service. GE is pushing later offerings such as Predix.
Ignition MES uses a modular approach and is an excellent add-on to the Ignition SCADA platform. It covers common MES functionality such as Downtime, OEE, Traceability… but does not cover some of the rarer aspects that other offerings cover. It is a flexible, easily customised Java-based platform but requires the Ignition SCADA base modules and Java skills.
Opera MES is a mature offering from Italy. Its modular structure covers the basic Production (inc. Planning), Material, Quality, and Maintenance. It also includes predictive analysis extensions and is closely related to NCM AI, an artificial intelligence company. Customisation is possible by modifying stored procedures and Java. You can start with the production module (required for other modules) and then unlock the other modules as required by a simple licence change.
OSI PI is the most known and common historian on the market. From an engineering perspective, it has many quirky configuration methods; you either need someone who knows the product very well, or to limit yourself to the client tools. There are a lot of good client tools, but it is heavy on computing resources. Due to the number, complexity and ever-changing landscape of the client tools, direct vendor involvement is recommended.
Rockwell Vantage Point uses the OSI PI Historian (not the latest) to collect the data and “Inquity” to publish the data. In simple terms, if you can produce the report in Excel, you can publish the report to a web interface or email it. As such, it is only suitable for basic implementations. Rockwell has moved on from marketing this as a solution.
RSBizware was an early player and had technical issues that needed to be worked around; it was rarely engineered well. Rockwell has subsequently dropped it as a product line.
TrakSYS uses a server/web client approach. Configuration time is significantly less compared with other solutions, and it is lighter on resources. It comes with significant out-of-the-box functionality and can be customised and extended. Support from the USA, where the product originated, is terrific but, as with most overseas vendors, occurs overnight due to the time difference.
Vijeo (Citect) Historian reads and writes with CitectSCADA well and has basic clients. Even though Citect has a great trend engine, the historian recording is inefficient as it stores information using the relational MSSQL model. Back-filling of data works extremely well when you stop and start the historian cleanly, but it does not recover well from a crash. The product is still available but not heavily marketed.
Aveva (Wonderware) Historian (INSQL) is very good at collecting data. Like OSI, it has a massive set of add-on clients that most people get confused about and do not know which client is the right choice for them. It can handle a lot of data. Due to the number, complexity and ever-changing landscape of the client tools, direct vendor involvement is recommended.
Through Mescon’s many years of experience across a broad range of solutions, both vendor-based and custom, we have learnt many things. For example, engaging experts as a part of your team early in your journey along the digitisation pathway removes confusion; you are more likely to get the best solution possible. One of the most significant factors in a successful journey is acknowledging that there isn’t a one-stop-shop solution. No one is an expert in all aspects of integrating business and production systems, and there needs to be a collaborative approach.
