Despite all the talk about smart factories and digital transformation, many manufacturers still struggle to get people to actually use their Manufacturing Execution System (MES).
The reality is sobering: up to 80% of MES projects stall at the pilot phase, and even when systems go live, users often fall back to spreadsheets or paper logs. The technology may be powerful, but without genuine user adoption, its value never materializes.
Let’s unpack why this happens—and more importantly, what you can do to make your MES something your team wants to use, not something they have to.
Most MES projects fail not because the software doesn’t work, but because it doesn’t fit the way people actually work.
Factories are living, breathing ecosystems—full of tribal knowledge, unique workflows, and seasoned operators who know every sound their machines make.
Drop a rigid digital system into that environment without empathy, and it’s bound to meet resistance.
Common human barriers to adoption include:
In other words—it’s not a technology problem; it’s a change management problem.
From our field experience, three recurring themes explain why user adoption lags:
Traditional MES systems often require months (or even years) of customization to match real processes.
Once live, they’re difficult to change.
If the MES doesn’t adapt to how people work—operators adapt by not using it.
Extended projects drain enthusiasm.
By the time a full deployment is complete, the shop floor has changed, key champions have moved on, and excitement has faded.
Clunky interfaces and “one-size-fits-all” dashboards discourage engagement.
Operators don’t want to dig through menus or enter redundant data. Especially if the system feels slower than their clipboard.
This is why modern MES platforms are being rebuilt around configurability, role-based UX, and faster time-to-value. They don’t force a single way of working, they flex with your processes.
Based on industry research and countless implementation lessons learned, here are five practices that consistently turn MES skeptics into advocates:
Before the first training session or go-live, employees need to understand why the MES matters.
Communicate how it helps them: fewer manual entries, faster issue resolution, easier audits, and less firefighting.
Tie the initiative to a bigger purpose like improving quality, safety, or customer delivery, not just “digital transformation.”
Don’t design the MES in a conference room. Bring operators, quality inspectors, and supervisors into the configuration process early. Their insights about daily workflows are invaluable and when they help shape the system, they’ll also defend it.
Pro Tip: Identify “super users” on each shift to act as internal champions. Peer-to-peer support beats IT memos every time.
Too often, training covers software features rather than job tasks.
A production operator doesn’t need to know every MES function—just the few screens they’ll touch daily. Build confidence through hands-on, scenario-based training, ideally in a sandbox environment where mistakes don’t matter.
If the MES takes longer than a spreadsheet, it won’t get used.
Simplify forms, automate repetitive steps (like barcode scanning instead of typing), and hide fields irrelevant to certain roles.
A good rule: if users can’t navigate it without a manual, it’s too complicated.
Highlight early success stories.
“Line 2 reduced scrap by 10% after going digital.”
“Our batch release time dropped from 3 days to 6 hours.”
Visible, tangible proof motivates others to engage as it shows the system isn’t just another IT project, it’s a performance enabler.
Modern MES platforms have evolved dramatically. Gone are the days of rigid, monolithic systems.
The new wave (often described as composable, low-code, or configurable MES) puts adaptability at the forefront.
Configurability enables:
In short: a configurable MES bends with the business instead of breaking under it.
When users see their feedback reflected in the next update or workflow improvement, they stop seeing MES as a burden and start seeing it as their system.
To know whether adoption is working, track metrics that combine operational and behavioral impact:
If adoption stalls, those numbers will tell you where—and why.
MES adoption isn’t a checkbox on a project plan; it’s a cultural shift.
Technology alone doesn’t transform factories—people do.
The manufacturers seeing success aren’t just deploying software. They’re engaging teams, simplifying technology, and embracing configurability as a path to agility.
The MES becomes less of a system to “use,” and more of a trusted digital companion that helps every worker perform at their best.
When that happens—the software fades into the background, and the factory finally runs the way it was meant to: connected, data-driven, and continuously improving.
Interested in implementing an MES? Schedule a meet with one of our experts.