Discrete Manufacturing

Discrete manufacturing brings forth many challenges, such as the need for flexible adaptation to current customer requirements, market demands, or the specifics of a given product. Specialized systems for discrete manufacturing can be the answer to the needs of manufacturers in this sector. Such systems facilitate process control, help implement even unexpected changes efficiently, quickly identify potential problem sources, manage quality, and much more.

What is Discrete Manufacturing?

Discrete manufacturing is one of the main forms of production, focusing on manufacturing items in an individual way. It differs from process manufacturing, which involves continuous production of a specific product, and batch manufacturing, where processing occurs in batches.

In practice, the products made in discrete manufacturing are concrete, individual, countable and sometimes serialized. Each is a distinct entity, like a car, a piece of furniture, or a computer. One facility can manufacture various products, each with its own specifications.

Discrete manufacturing can include raw material processing, prefabrication, assembly of different components, quality testing, and packaging. Later in the process, these elements can be parts of larger items, but they are separate entities on their own – visible, tangible, and countable.

Discrete manufacturing industries

The flexibility of discrete manufacturing facilitates using individual components in various configurations and incorporating additional elements. Thanks to this, products can be customized to individual customer needs or quickly changing market trends. Discrete manufacturing is prevalent in many industries, including:

Automotive
and Aerospace

Producing cars, motorcycles, trucks, airplanes, as well as their parts and components like engines, shock absorbers, and interior elements.

Electronics

Producing computers, phones, televisions, and various electronic components.

Machinery

Producing various types of machines, tools, and industrial equipment.

Furniture

Producing furniture and other wood products.

Major Challenges in Discrete Manufacturing and How to Overcome Them

Integrating All Stages of the Process

Manufactured products often consist of many parts from different suppliers. Ensuring the availability of all elements and the smooth execution of their assembly is crucial for seamless running of the entire process.

  • MES (Manufacturing Execution System): Helps integrate the process by automatically tracking each production stage, providing information about available resources, individual operations, and deliveries. The system aids smooth collaboration between warehouse, logistics, and production.
  • APS (Advanced Planning and Scheduling): Creates plans and schedules for various departments based on data from MES, taking account of numerous factors and integrating elements of even the most complex processes.

Effective Inventory Management

Both excessive stockpiling and shortages are problematic. Excess leads to storage issues and generates unnecessary costs, while shortage of even one element can cause delays and disrupt the whole production schedule.

  • MES: Tracks the flow of materials and semi-finished products in real time, from the beginning to the end of the process. This enables users to monitor usage, identify deficiencies, and take appropriate action to prevent both production halts and overstocking.
  • APS: Its functionalities are particularly beneficial in supporting smooth MRP (Material Requirements Planning) run and ensuring effective planning of subproduct manufacturing and order preparation.

High Variability and Customization of Products

Adapting to individual customer needs, changing industry requirements, and ever-advancing trends requires flexibility, which can only be achieved with appropriate manufacturing management tools. Traditional planning methods using spreadsheets or basic ERP systems can be too time-consuming and inefficient.

  • APS: As a professional scheduling system, it can generate both simple and complex plans within seconds, considering various factors. With the “What if” functionality, it facilitates the analysis of various options and alternative scenarios, which can be compared to choose the best version.
  • MES: Flexible modeling of production technologies supports manufacturing execution even with high variability and short series.

Order Changes

In discrete manufacturing, order modifications are not uncommon. Changes in orders, such as delivery dates, quantities, or variants, are a major obstacle and require frequent schedule updates and increased workload, for example in the form of overtime.

  • APS: Thanks to advanced algorithms, the system quickly reacts to changes and unexpected situations, generating updated plans that account for new requirements.
  • MES: Through advanced integration mechanisms, any changes at the level of ERP and APS are promptly transferred to MES and implemented in production.

Short Delivery Times

Efficiency in meeting promised delivery times enhances competitiveness and builds customer trust. Eliminating unnecessary operations and optimizing schedules is key for quick and seamless delivery.

  • MES: By automatically collecting detailed information on the entire process, the system helps identify inefficient actions that affect product development process.
  • APS: allows realistic delivery time estimation using the Capable-To-Promise function.

Bottlenecks

Identifying and eliminating process bottlenecks is essential for preventing delays. This can only be done with detailed knowledge about what happens at every stage of production.

  • MES: Provides detailed knowledge of production stages, helping identify problematic areas and eliminate the underlying cause.
  • APS: By reporting real work progress from MES to APS, it is possible to detect potential performance issues and react accordingly by adjusting resources and schedules as needed.

Unforeseen Downtimes and Failures

Unexpected machine downtimes can disrupt the whole production process and cause significant delays. Although they cannot be eliminated entirely, continuous monitoring can minimize their impact by addressing problematic issues immediately after they occur.

  • MES: Monitors key parameters of machine and manufacturing line operation in real-time, identifying causes of downtimes and issuing alerts for preventive actions.
  • APS: Facilitates quick response to changing resource availability, eliminating the missing resources from production plan, remodeling the schedule, and sending it as an update.

MES in Discrete Manufacturing: How It Helps

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APS for Discrete Manufacturing Planning: Discover the Benefits

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Partner | Business Development

“The rapidly changing consumer habits and needs force manufacturing companies to dynamically adapt. Manufacturing Execution Systems can support them by facilitating the recording of changes, efficient modification of product configuration, and collecting comprehensive information on the entire process. This allows for increased production while reducing variable costs (e.g., labor, raw materials) and even fixed costs (e.g., minimizing the space occupied by machinery).

Savvy managers leverage MES to automate information flow while maintaining data reliability, in line with the principle of ‘management by facts.’ As a result, they can save their employees’ time and eventually move the decision-making points closer to the process, further enhancing the organization’s agility.”

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Partner | Business Development

“The increasing pace of production, greater product variety, along with smaller order sizes and the need to minimize inventory, are the challenges faced by discrete manufactures nowadays. At the same time, they are under immense pressure to ensure quick and timely deliveries. All these factors make the shortcomings of production scheduling with ERP systems or spreadsheets increasingly apparent. Typically, these tools do not allow for the creation of schedules that account for all necessary factors and serve as a valuable guide for production. However, Advanced Planning and Scheduling solutions offer this capability. APS systems provide precise and optimized guidelines for the order sequence and enable rapid adjustments to schedules in response to changes in production or supply situation, often within seconds.”

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Free Brochure

How It Works in Practice: Download a free brochure on how MES supports the automotive industry in discrete manufacturing

    Download the free brochure and discover the benefits of implementing an MES system


    In this brochure, using the automotive industry as an example, we show which MES functionalities can be particularly useful in discrete manufacturing.

    Success Stories

    Discover how discrete manufacturing companies benefit from implementing professional manufacturing support systems
    mes-logo

    Brose Sitech
    Automotive Industry

    Marta Gaworczak, Division Manager Procurement

    “We highly recommend Improvement Factory Sp. z o.o. as a reliable and competent partner, who meets high-quality standards and demonstrates excellent customer service.”

    mes-logo

    VIGO Photonics
    High-Tech Electronics

    Łukasz Piekarski
    CFO at VIGO Photonics

    “Implementing the MES system was only part of the successful transformation of the company and the implementation of new operating standards. The introduction of new management systems, using appropriate IT tools, including the MES system, allowed VIGO Photonics to increase production, save time and reduce the number of complaints and significantly increase profits”

    mes-logo

    DOVISTA
    Windows and Doors

    Tomasz Kubach
    ERP Program Officer at DOVISTA

    “The two key tasks that MES faces in our organization are to provideup-to-date information about the production plan, as well as accurate dataon the technology of each window element at the place of its manufacture or processing. As part of the provision of technology in this area is also the creation of files with programs for CNC machines.”

    Articles

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    FAQ

    1.

    What is MES and what benefits does it bring to discrete manufacturing?

    MES (Manufacturing Execution System) is software that supports real-time manufacturing operations management. MES in discrete manufacturing helps improve efficiency, track processes, reduce waste, enhance product quality, and provide better production order control.

    2.

    What are key functionalities of APS

    System APS (Advanced Planning and Scheduling) umożliwia zaawansowane planowanie i harmonogramowanie. APS w produkcji dyskretnej przynosi takie korzyści jak: optymalizacja wykorzystania zasobów, planowanie produkcji w oparciu o dostępność materiałów i maszyn, zarządzanie terminami realizacji zleceń, a także przewidywanie i minimalizowanie opóźnień. 

    3.

    What are the differences between MES and APS?

    MES focuses on real-time production monitoring and management, while APS is used for production planning and scheduling. MES provides current production data, while APS helps create optimal production plans.

    4.

    Can MES and APS work together?

    Yes, integrating MES and APS creates an efficient production management solution. APS provides optimal plans, executed and monitored by MES. This cooperation ensures better production planning and execution, leading to higher efficiency and flexibility of production processes.

    5.

    Can MES improve the quality of discrete manufacturing?

    MES closely monitors each production stage, quickly identifying and correcting errors, maintaining high product quality, reducing waste, and eliminating quality issues. MES facilitates tracking and documenting all operations, which simplifies the auditing process and helps to meet quality requirements.

    6.

    What are the challenges in implementing MES and APS in discrete manufacturing?

    Challenges in implementing MES and APS include integration with existing ERP and IT systems, the need to train employees, managing organizational changes, and adapting the systems to the specific needs and processes of an enterprise. What is more, the implementation often involves high initial costs.

    7.

    What are the best practices for implementing MES and APS?

    Best practices include conducting thorough analysis of the needs and production processes before implementation, choosing systems that fit the specific nature of the enterprise, engaging stakeholders in the implementation process, and providing suitable training to employees. You should also remember to implement the systems gradually, regularly monitor their functioning, and make necessary adjustments.

    8.

    What are the business benefits of MES and APS implementation?

    The business benefits of MES and APS in discrete manufacturing include increased production efficiency, better resource utilization, reduced operational costs, improved product quality, shorter order fulfillment times, and greater flexibility to market changes. As a result, the enterprise can increase competitiveness and achieve better financial results.

    9.

    How to choose the right system for discrete processes?

    There are no universal principles to choosing the specific system for discrete manufacturing. Each company should be treated individually, based on a needs analysis and specific processes. You should also consider system scalability and compatibility with existing solutions. It is worth choosing a provider who offers not only a product but also implementation support and ongoing assistance.

    10.

    What machines and manufacturing operations are typically involved in discrete processes?

    Discrete processes are associated with various types of raw material preprocessing and element prefabrication. Therefore, companies in this sector typically use machinery such as CNC stations (numerical machines), saws, presses, rolling machines, milling machines, lathes (generally machining equipment), as well as assembly stations. Corresponding operations include cutting, stamping, rolling, milling, turning, machining, and assembly.