MES & Maintenance Software: How to Connect Production and Maintenance
A machine stops, production waits – and every minute costs money. In modern manufacturing with millions invested in equipment, every additional hour of uptime counts. Yet, the digital chain often breaks exactly where it’s most expensive: in maintenance.
This scenario is still everyday reality in many factories, even though a modern MES (Manufacturing Execution System) is already in use. When it comes to maintenance, troubleshooting, or preventive maintenance, many systems reach their limits. While error messages are logged in the MES, the actual maintenance work still runs on Excel, paper, or by phone. That’s where remberg comes in: as maintenance software that connects seamlessly with MES systems, it bridges the gap between production and maintenance – for smooth, media-break-free processes.
MES at a Glance – Strong in Production, Limited in Maintenance
An MES forms the backbone of production. It controls and documents your batch manufacturing and provides key metrics such as OEE. But when it comes to keeping machines running at peak performance to meet production goals, it quickly becomes clear: in most MES systems, maintenance is only a footnote.
Many remberg customers using systems like Hydra, WinCC, FlexNet, MPDV, or next-generation MES platforms such as Tulip confirm this. Their MES handles production control – but maintenance and troubleshooting are separate. The result: media breaks and duplicate data entry.
More Production Through Less Downtime
Companies are willing to invest heavily in an MES to gain even a single-digit increase in production – because that’s their lifeblood. Every additional hour of uptime means more output, more revenue, and faster ROI on production assets.
When MES and maintenance software like remberg work hand in hand, that’s exactly what happens: less downtime, faster response times, and greater transparency for both planned and unplanned stops. Every 1% increase in equipment availability can mean hundreds of extra production hours per year.
That’s how preventive maintenance becomes a true competitive advantage: you produce more – with the same equipment, the same people, and the same MES.
remberg Complements the MES Where It Stops
Instead of seeing MES and maintenance software as opposites, leading companies use both – with clear task separation and smart integration.
The MES focuses on production data, OEE, and process stability. remberg ensures that machines run longer, technicians respond faster, and production targets are consistently met.
Example: Breakdown Reporting Process with remberg and MES Integration
The difference between analog and integrated maintenance becomes most visible in a breakdown example.
Without integration: downtime, lost time, no transparency
In the past: error, phone call, paper, Excel – chaos.
A malfunction is reported via phone or WhatsApp, a paper order is written, spare parts checked manually, and forms filled out. After repair, the feedback is written by hand, then transferred into Excel or a PDF, and finally posted manually in the ERP.
The result: no direct link between failures, costs, spare parts, and KPIs.
Decisions take longer, errors occur more often, and transparency is missing.
With remberg + MES: fully digital process
Today, the same issue looks completely different:
The MES detects the stoppage or an operator reports it digitally.
In remberg, a ticket is automatically created with asset ID, photo, and priority. The system notifies the right technicians, creates a digital work order with checklist, and checks part availability via MES/ERP.
After completion, the feedback is logged digitally and synchronized with MES and ERP. Costs, spare parts, and KPIs update in real time.
How MES & remberg Boost Efficiency, Transparency, and Uptime
When MES and remberg are integrated, a continuous data chain is created – from failure notification to maintenance to restart.
Clear advantages:
- More equipment uptime: maintenance triggered automatically by real operating data
- Less downtime: notifications go directly to the right technician – no detours
- Higher data quality: production and maintenance data combine for more precise KPIs (e.g. MTTR, MTBF, OEE)
- Streamlined processes: no Excel sheets, no double entries, no information gaps
- Better collaboration: production and maintenance share the same data flow – everyone sees what the other does
Interfaces That Work – How remberg Integrates with Your MES
remberg integrates to common MES systems like Hydra, WinCC, FlexNet, or MPDV via standardized interfaces. Integration can happen at the IT layer via API, MQTT, or CSV import – depending on your IT setup.
Examples:
- Automatic data exchange of operating hours and counters
- Automatic creation of maintenance orders from MES error messages
- Feedback of completed work orders back to MES or ERP (e.g. SAP)
Your existing system landscape remains intact – and remberg becomes the maintenance system that connects everything.
Bonus: automatically transferring spare parts, costs, and labor hours to ERP makes not only maintenance more efficient, but also purchasing, controlling, and production planning. The integration of remberg therefore increases the value of your ERP system.
Find more information about our interfaces in the remberg Developers Hub.
ROI & Business Impact – Why Integration Pays Off
Many ask: “Why do I need remberg if my MES already does everything?”
The answer: specialization. remberg is built for maintenance – with a focus on ease of use, mobile workflows, and automation.
Digitally connecting your maintenance with your MES not only reduces manual effort but also increases production time. Reducing unplanned downtime by just 1% can – at 6,000 annual operating hours – mean 60 extra production hours. Multiplied by production cost or margin, this can quickly add up to a six-figure impact.
The result:
- Up to 30% less time spent on work order processing
- Higher uptime through preventive maintenance
- Better traceability for audits and compliance
- Faster troubleshooting through mobile maintenance
Where MES Stops, remberg Begins
In connected manufacturing, every move counts – in the control room or at the machine. Integrating remberg into your MES creates a seamless bridge between production and maintenance.
Error messages automatically become work orders, maintenance is based on real operating data, and all activities are fully documented. The result: not only efficient but also reliable production.
Every minute of production time matters. By integrating remberg into your MES, you ensure that every asset runs as it should – longer, more efficiently, and with fewer interruptions. Because in the end, it’s not software that determines your success, but the availability of your production.
FAQ: Common Questions About MES and remberg Integration
What’s the difference between MES and maintenance software?
An MES controls production processes and monitors manufacturing KPIs. Maintenance software like remberg manages maintenance, failures, spare parts, and asset lifecycles – ensuring long-term machine availability.
How does the integration between MES and remberg work technically?
Via standardized interfaces such as API or OPC UA, production and operating data are automatically synchronized with remberg. This enables maintenance or tickets to be triggered directly from MES events.
Can remberg be used with my existing MES?
Yes. remberg offers flexible integrations for systems like Tulip, Hydra, MPDV, WinCC, or FlexNet – and can also connect with ERP systems such as SAP.
What are the benefits of integration?
Less downtime, higher equipment availability, media-break-free processes, and improved collaboration between production and maintenance.