Struggling with inefficient production tracking, manual data entry errors, or disconnected factory systems? Off-the-shelf Manufacturing Execution Systems (MES) often force UK manufacturers into rigid workflows that don’t match their unique processes. At ByteGears, we build custom MES solutions designed around your existing operations—not the other way around.
Unlike generic SaaS platforms with expensive recurring fees, our UK-developed systems give you complete ownership and control. We specialise in creating tailored manufacturing software that integrates seamlessly with your machinery, ERP systems, and quality control processes. With local developers who understand British manufacturing standards, we deliver solutions that improve visibility, reduce waste, and scale with your business—all without disruptive workflow changes.
Why Off-the-Shelf Manufacturing Execution Systems Fall Short
Generic MES solutions often create more problems than they solve for UK manufacturers. Here’s what we consistently hear from frustrated business owners:
- Misfit workflows: Pre-built systems require you to adapt your processes to the software, not vice versa
- Hidden costs: Monthly SaaS fees accumulate far beyond the cost of custom development
- Integration gaps: Limited API access creates data silos between your MES and other business systems
- One-size-fits-all approach: Unable to accommodate unique production lines or quality control requirements
- Compliance risks: Offshore solutions may not meet UK GDPR and industry-specific regulations
These limitations lead to costly workarounds—manual spreadsheets, duplicate data entry, and inefficient approvals that undermine the very efficiency gains MES should provide. When software doesn’t fit, employees develop shadow systems that bypass the MES entirely, leaving management with unreliable data.
The ByteGears Custom Manufacturing Execution Systems Difference
Our UK-based team builds Manufacturing Execution Systems that work the way you do. Here’s how our approach delivers lasting value:
Process-Focused Design
We start by mapping your current workflows—from shop floor data collection to quality assurance—then design software that enhances rather than disrupts your operations. No forced process changes.
One-Time Investment
Eliminate perpetual SaaS fees. Our custom MES becomes your business asset, with predictable support costs and no vendor lock-in.
Seamless Integration
Native connections to your ERP, PLCs, barcode scanners, and other systems ensure real-time data flow across your operations.
UK Compliance Built-In
From GDPR to industry-specific standards like ISO 13485 for medical devices, we bake compliance into your system’s architecture.
Scalable Architecture
Modular design allows adding new production lines, reporting dimensions, or IoT device integrations as your needs evolve.
Local Support
Our London-based team provides implementation support and responsive maintenance—no overseas call centres or timezone delays.
Essential Manufacturing Execution Systems Features We Deliver
Every ByteGears MES includes these core capabilities, tailored to your specific requirements:
- Real-Time Production Monitoring: Track work orders, machine states, and operator inputs with live dashboards
- Quality Management: Built-in SPC charts, non-conformance tracking, and corrective action workflows
- Material Traceability: Full lot/batch tracking from raw materials to finished goods
- OEE Calculation: Automatic Overall Equipment Effectiveness metrics by line, shift, or machine
- Custom Reporting: Configurable KPIs with role-based dashboards for managers and operators
- Mobile Accessibility: Tablet/phone access for floor supervisors with offline capability
- Electronic Work Instructions: Dynamic guides with multimedia support for complex assemblies
- Maintenance Scheduling: Predictive alerts based on machine runtime or cycle counts
- Energy Monitoring: Integration with smart meters for sustainability reporting
- UK Data Security: Encrypted data storage with audit trails meeting BS 10012 standards
How We Deliver Your Custom Manufacturing Execution Systems
Our proven four-phase approach ensures your MES delivers maximum value:
1. Discovery & Planning (2-4 weeks)
We document your current processes, pain points, and integration requirements through workshops with key stakeholders.
2. Custom Development (8-16 weeks)
Agile development of your core MES modules with biweekly demos for feedback. Typical projects include:
- Data model configuration
- UI/UX design matching operator workflows
- API development for system integrations
- Role-based access controls
3. Testing & Deployment (2-4 weeks)
Pilot testing on your shop floor followed by phased rollout with fail-safes to prevent production disruption.
4. Training & Support (Ongoing)
Comprehensive training for all user levels plus 12 months of included support with UK-based response teams.
Understanding the Investment in Custom Manufacturing Execution Systems
While custom development requires upfront investment, our clients typically see:
- Cost predictability: No surprise SaaS price hikes or per-user fees
- Long-term savings: 3-5 year total cost often below SaaS alternatives
- Process efficiencies: Typical ROI through reduced scrap, faster changeovers, and better labour utilisation
- Asset ownership: Your system appreciates as a business asset rather than an expense
Project costs vary based on factory size, integration complexity, and reporting needs. During your free consultation, we’ll provide transparent pricing based on your specific requirements.
Manufacturing Execution Systems Applications Across Industries
Custom MES solutions benefit diverse UK manufacturing sectors:
- Automotive: Track serialised components through multi-stage assemblies
- Pharmaceutical: 21 CFR Part 11 compliant electronic batch records
- Food & Beverage: Recipe management with allergen controls
- Aerospace: AS9100 compliant non-conformance tracking
- Electronics: Component-level traceability for recalls
- Medical Devices: UDI compliance and sterilisation lot tracking
- Packaging: Job costing with material yield optimisation
- Chemicals: EH&S integration for SDS management
- Fabrication: Machine utilisation reporting across CNC equipment
- Contract Manufacturing: Customer-specific workflow configurations
Common Questions About Custom Manufacturing Execution Systems
1. How does custom development cost compare to SaaS solutions?
While custom MES requires higher initial investment, total 5-year costs are typically 30-50% lower than SaaS subscriptions. You also avoid vendor lock-in and gain system ownership.
2. What’s the typical development timeline?
Most projects deliver core functionality in 3-5 months. Complex integrations or multi-site deployments may take longer. We provide timeline estimates after requirements gathering.
3. How do you handle updates and changes?
All systems include 12 months of support. Thereafter, we offer flexible support contracts. Updates are applied without disrupting production schedules.
4. Can you integrate with our existing systems?
Yes—we regularly integrate with ERP (SAP, Sage, NetSuite), PLCs (Siemens, Allen-Bradley), and quality systems (LIMS, QMS). Legacy system compatibility is assessed during discovery.
5. What about data security and compliance?
All solutions include UK GDPR-compliant data handling, encrypted communications, and role-based access. Industry-specific standards (ISO, GMP) are implemented as required.
6. Do you provide training for our team?
Comprehensive training covers system administrators, supervisors, and shop floor operators. We provide custom manuals and video tutorials for ongoing reference.
Ready to Explore Custom Manufacturing Execution Systems?
Take the first step toward a manufacturing system designed for your business:
- Schedule your free consultation: 30-minute discovery call to discuss your requirements
- Receive a tailored proposal: Detailed scope, timeline, and investment estimate
- Start development: Typically within 2 weeks of project approval
Contact our London team today:
📞 020 8191 1816
📧 [email protected]
📍 27 Old Gloucester Street, London, WC1N 3AX
We accept a limited number of MES projects each quarter to ensure exceptional service quality. Reach out now to discuss availability.