From Execution to Intelligence: A Data-driven Approach to Modern Manufacturing

Estimated reading time: 2 minutes

Critical Manufacturing is pushing the boundaries of the Manufacturing Execution System (MES) beyond traditional limits with contextualized data, flexible configurability, and modular and structural architecture, all built with intent on Machine Learning and AI fundamentals, allowing customers to decide independently whether certain data is important. The MES is, in fact, the backbone of digital transformation in manufacturing with a built-in data platform. 

In this discussion, Augusto Vilarinho, an MES expert at Critical Manufacturing, explores the essential functions of MES in tracking and tracing shop floor activities where AI and machine learning capabilities are purposely built into the MES through it's embedded data platform, capturing all machine data, integrating and connecting with different systems, ERPs, physical equipment, and people. 

“Our technology allows us to capture and absorb data that may scale up to massive volumes of information”, Augusto explains. He also addresses common challenges and misconceptions around implementing MES, AI, and ML. Successful adoption, he notes, hinges on proper planning and execution. When done right, the embedded data platform not only supports real-time decision-making but also drives long-term, continuous improvement across manufacturing operations.

Barry Matties: Augusto, explain a little bit about the MES system and why people should be thinking about it.

Augusto Vilarinho: We've been seeing, reading, and hearing much about MES as the backbone of the digital industry. The system can capture information from the shop floor, track and trace what is happening physically in a digital format, and ensure adequate degrees of quality as established in the quality procedures. MES can ensure adequate equipment utilization and equipment efficiency.  MES can support all those things, guiding the operations to become more productive, and create more efficient processes and better quality.

MES makes complete sense because it aggregates and gathers all those aspects in one single system that then can serve and be utilized for continuous improvement processes.

Matties: Bringing in a system is a big process that requires a significant investment. What are some misconceptions about what it takes to launch an MES system in a factory?

Vilarinho: An MES project is always a bit disruptive to operations because if a shop does not have a system that controls and monitors its work and how the work should be performed, it is basically people executing it in their own minds and doing things how they have always done them. An MES project will bring discipline and require the operators to do things not required when they had no controls on their system. It's commonly known that an MES project is very complex. It requires time and effort. In our experience, the more an organization is prepared to enter into an MES project, the less disruption and complexity it will have—and the less time and costs it will have.

To read this entire conversation, which appeared in the May 2025 issue of SMT007 Magazine, click here.