North Carolina manufacturers need an ERP system for business operations (financials, inventory, planning) and an MES for shop-floor execution (real-time production tracking, quality control, machine monitoring). Most mid-market manufacturers with 50 or more employees benefit from both systems working together, while smaller shops may start with ERP alone and add MES capabilities as they grow.
Key takeaway: According to IoT Analytics' 2025 MES market research, only 8% of the world's roughly 5 million factories currently use a commercial MES system, representing a massive untapped opportunity for manufacturers to gain competitive advantage through production visibility. Meanwhile, the MES market has reached $5.5 billion globally and is growing at 10-17% annually, reflecting accelerating adoption.
For manufacturers across North Carolina's Piedmont Triad, from furniture producers in High Point to automotive suppliers in Charlotte and aerospace manufacturers in the Research Triangle, choosing between MES and ERP, or implementing both, represents one of the most consequential technology decisions for operational performance and competitiveness.
Need guidance on manufacturing systems for your NC operation? Preferred Data Corporation provides custom software solutions and manufacturing technology consulting for North Carolina manufacturers. With 37+ years of expertise and BBB A+ accreditation, we help you choose and implement the right systems. Call (336) 886-3282 or schedule a consultation.
Understanding ERP: The Business Side of Manufacturing
An Enterprise Resource Planning (ERP) system is the backbone of manufacturing business operations. It manages everything above the shop floor: financials, inventory, procurement, human resources, customer relationships, and business planning.
What ERP Does for NC Manufacturers
- Financial management: General ledger, accounts payable/receivable, cost accounting
- Inventory control: Raw materials, work-in-progress, finished goods tracking
- Production planning: Master production scheduling, material requirements planning (MRP)
- Supply chain management: Purchase orders, vendor management, receiving
- Sales and order management: Quoting, order entry, shipping, invoicing
- Human resources: Payroll, time tracking, benefits administration
ERP Market Context
According to industry analysis, the global ERP market reached approximately $73 billion in 2025, with manufacturing representing 32% of all ERP deployments, the largest industry vertical. Cloud ERP is growing at 14.5% CAGR while on-premise solutions grow at only 2%.
For North Carolina mid-market manufacturers (50-500 employees) in Greensboro, Winston-Salem, and High Point, common ERP options include:
- Epicor Kinetic: Strong in discrete manufacturing, popular in NC metalworking and plastics
- Infor CloudSuite Industrial (SyteLine): Excellent for complex, engineer-to-order manufacturers
- Microsoft Dynamics 365: Broad functionality with strong Microsoft ecosystem integration
- SAP Business One/S/4HANA: For larger manufacturers needing global supply chain capabilities
- Acumatica: Cloud-native option growing rapidly in mid-market manufacturing
Understanding MES: The Shop-Floor Side
A Manufacturing Execution System (MES) lives on the production side of the factory. It monitors and controls manufacturing processes in real time, providing visibility into what is actually happening on the shop floor versus what was planned.
What MES Does for NC Manufacturers
- Real-time production tracking: Actual vs. planned output, cycle times, throughput
- Quality management: In-process inspections, SPC (statistical process control), NCR tracking
- Machine monitoring: OEE measurement, downtime tracking, performance analysis
- Labor tracking: Operator productivity, skill-based assignments, certifications
- Genealogy and traceability: Lot tracking, material traceability, recall management
- Work instructions: Digital work instructions, visual aids, process documentation
- Scheduling and dispatching: Real-time job prioritization, resource allocation
The MES Value Proposition
According to Fortune Business Insights, the global MES market is valued at $16.57 billion in 2025 and projected to reach $41.78 billion by 2032, growing at 14.10% CAGR. This growth reflects manufacturers recognizing that ERP alone cannot provide the real-time shop-floor visibility needed for operational excellence.
For Piedmont Triad manufacturers still relying on paper travelers, whiteboard scheduling, or spreadsheet-based tracking, MES provides the digital foundation for data-driven production management.
MES vs. ERP: Key Differences
| Factor | ERP | MES |
|---|---|---|
| Focus | Business operations | Production execution |
| Time horizon | Days, weeks, months | Seconds, minutes, hours |
| Data type | Transactional | Real-time operational |
| Users | Finance, purchasing, planning | Operators, supervisors, quality |
| Update frequency | Batch/periodic | Continuous/real-time |
| Decision support | Strategic/tactical | Operational/immediate |
| Integration | Suppliers, customers, finance | Machines, PLCs, sensors |
Simple analogy for NC manufacturers: ERP tells you what to make, when, and with what materials. MES tells you how it is actually being made right now, whether quality targets are being met, and which machines are running or down.
When NC Manufacturers Need Both Systems
Indicators You Need MES (Beyond ERP)
Most North Carolina manufacturers with 50+ employees and multiple production lines should evaluate MES if they experience:
- [ ] Production visibility gaps (cannot answer "what is happening on the floor right now?")
- [ ] Quality issues not caught until final inspection or customer complaint
- [ ] Inaccurate labor and machine utilization data
- [ ] Inability to trace materials through production (compliance risk)
- [ ] Scheduling conflicts between ERP plan and actual floor capacity
- [ ] Paper-based processes on the shop floor
- [ ] Customer audit requirements for real-time production records
Indicators ERP Alone Is Sufficient
Smaller manufacturers in High Point, Thomasville, or Kernersville with simpler operations may manage with ERP alone if:
- Single production line or cell
- Fewer than 30 shop-floor employees
- Low product complexity or variation
- No regulatory traceability requirements
- Manual scheduling works effectively at current volume
Integration Approaches: Making MES and ERP Work Together
The critical question for NC manufacturers is not just which system to buy, but how to make them communicate effectively. Poor integration creates data silos that negate the value of either system.
Approach 1: Same-Vendor Integration
Some vendors offer both ERP and MES in a unified platform, eliminating integration challenges.
Examples:
- Epicor Advanced MES (formerly Mattec) integrated with Epicor Kinetic
- Infor OS connecting CloudSuite Industrial with Infor MES
- SAP Manufacturing Integration and Intelligence (MII) with S/4HANA
Pros: Seamless data flow, single vendor relationship, unified support Cons: May sacrifice best-of-breed functionality, vendor lock-in
Approach 2: Best-of-Breed with Middleware
Select the best ERP and MES independently, then connect them through integration middleware or APIs.
Common MES options for NC mid-market:
- Plex (now Rockwell Automation): Cloud-native, strong for automotive and food
- AVEVA MES (formerly Wonderware): Process and discrete manufacturing
- Aegis FactoryLogix: Electronics and complex assembly
- 42Q: Cloud-based, rapid deployment for discrete manufacturing
- Tulip: No-code platform for custom manufacturing apps
Pros: Best functionality in each category, flexibility to swap components Cons: Integration complexity, multiple vendor relationships, higher total cost
Approach 3: Phased Implementation
Start with ERP for business operations, then add MES capabilities incrementally.
Phase 1 (Months 1-6): Deploy ERP for financials, inventory, and basic production planning Phase 2 (Months 7-12): Add machine monitoring and OEE tracking (MES foundation) Phase 3 (Months 13-18): Implement quality management and traceability Phase 4 (Months 19-24): Deploy advanced scheduling and digital work instructions
This phased approach works well for growing Piedmont Triad manufacturers who need to manage change carefully while building toward full OT/IT integration.
Ready to evaluate your manufacturing systems options? Preferred Data Corporation helps North Carolina manufacturers select, implement, and integrate ERP and MES solutions. Call (336) 886-3282 or request a manufacturing technology assessment.
The Vendor Landscape for NC Mid-Market Manufacturers
ERP Selection Considerations
For North Carolina manufacturers with $10M-$500M revenue, the ERP decision should factor in:
- Industry fit: Does the vendor understand your specific manufacturing type (discrete, process, engineer-to-order)?
- Local support: Are implementation partners and consultants available in the Piedmont Triad or Charlotte area?
- Cloud vs. on-premise: Cloud reduces IT burden but requires reliable network infrastructure
- Scalability: Can the system grow from your current 50 users to 200+ without replacement?
- Integration capabilities: APIs and connectors for MES, CAD, and other manufacturing systems
MES Selection Considerations
- Machine connectivity: Does it support your specific equipment protocols (OPC UA, MTConnect, Modbus)?
- Deployment model: Cloud-based for faster deployment vs. on-premise for latency-sensitive applications
- Configurability: Can operators customize dashboards without developer support?
- Mobile access: Tablet and phone access for floor supervisors and quality staff
- Scalability: Can you start with one line and expand to the entire facility?
Cost Comparison for NC Mid-Market Manufacturers
ERP Investment (50-200 users)
- Software licensing: $50,000-$300,000 (or $100-$300/user/month for cloud)
- Implementation services: $100,000-$500,000
- Data migration: $20,000-$75,000
- Training: $15,000-$50,000
- Annual maintenance: 18-22% of license cost (on-premise) or included (cloud)
MES Investment (1-5 production lines)
- Software licensing: $50,000-$200,000 (or $500-$2,000/month per line for cloud)
- Machine connectivity and sensors: $5,000-$20,000 per machine
- Implementation services: $50,000-$200,000
- Training: $10,000-$30,000
- Annual maintenance: Similar structure to ERP
Integration Costs
- Middleware/API development: $20,000-$75,000
- Ongoing integration maintenance: $2,000-$5,000/month
Industry 4.0 and the Convergence of MES and ERP
The boundaries between MES and ERP are blurring as both categories evolve toward Industry 4.0 capabilities. For North Carolina manufacturers investing in AI transformation, the integration of these systems provides the data foundation for advanced analytics, predictive maintenance, and autonomous optimization.
According to Panorama Consulting's 2025 ERP Report, 72.6% of organizations have already deployed AI within their operations, driving demand for the real-time production data that MES provides and the business context that ERP delivers.
Key convergence trends:
- AI-powered demand sensing connecting ERP planning with MES execution
- Digital twins requiring data from both business and production systems
- Predictive quality analytics spanning design (ERP/PLM) through production (MES)
- Autonomous scheduling optimizing across business constraints and floor reality
Implementation Best Practices for NC Manufacturers
Start with Process Before Technology
Before evaluating vendors, document your current manufacturing processes across your Greensboro, High Point, or Charlotte facilities. Understand what works, what does not, and where technology can add the most value.
Secure Executive and Floor-Level Buy-In
Manufacturing system implementations fail when either leadership or shop-floor workers resist change. Include operators in the selection process and demonstrate how the system makes their jobs easier, not harder.
Plan for Change Management
Budget 15-20% of your total project investment for change management, training, and process redesign. Technology alone does not transform operations; people and processes must adapt alongside it.
Partner with Local Expertise
Work with implementation partners who understand North Carolina manufacturing, your specific industry vertical, and the unique challenges of mid-market companies. National firms often bring enterprise methodologies that overwhelm smaller organizations.
Frequently Asked Questions
Can I use ERP for shop-floor tracking without a separate MES?
Some modern ERP systems include basic manufacturing execution capabilities, such as shop-floor data collection and simple quality tracking. For smaller NC manufacturers with straightforward production processes, this may suffice. However, if you need real-time machine monitoring, advanced quality management (SPC), or detailed traceability, a dedicated MES provides significantly deeper functionality.
How long does it take to implement MES for a mid-size NC manufacturer?
A typical MES implementation for a Piedmont Triad manufacturer with 3-5 production lines takes 6-12 months from vendor selection through go-live. Starting with a pilot line (2-3 months) before rolling out to additional lines reduces risk and builds internal expertise. Cloud-based MES solutions can deploy faster (3-6 months) than on-premise alternatives.
What is the ROI timeline for MES investment?
Most NC manufacturers see MES ROI within 12-18 months through improved OEE (typically 5-15% improvement), reduced quality costs (10-25% reduction in scrap/rework), and better labor utilization. Manufacturers with high compliance requirements (aerospace, medical, defense) often see faster ROI through reduced audit preparation time and documentation costs.
Should I replace my current ERP before adding MES?
Not necessarily. If your current ERP handles business operations adequately, adding MES for shop-floor visibility is often a better investment than a full ERP replacement. Modern MES systems integrate with most major ERPs through standard APIs. However, if your ERP is end-of-life or severely limiting operations, a combined ERP/MES evaluation may be more cost-effective.
How do MES and ERP work together for production scheduling?
ERP typically handles macro-level production planning (weekly/monthly schedules, MRP), while MES manages micro-level scheduling (real-time dispatch, sequence optimization, machine assignment). The integration point is usually the work order: ERP creates and releases work orders, MES executes and reports against them, and status flows back to ERP for costing and inventory updates.
Partner with High Point's Manufacturing Technology Experts
Preferred Data Corporation has served North Carolina manufacturers for over 37 years from our High Point headquarters. Our BBB A+ rated team understands the unique technology challenges facing Piedmont Triad, Charlotte, and Research Triangle manufacturers evaluating and implementing production systems.
How PDC helps with manufacturing systems:
- Manufacturing technology assessments and system selection guidance
- Custom software development for unique manufacturing requirements
- OT/IT integration connecting shop-floor equipment to business systems
- Network infrastructure designed for manufacturing environments
- Ongoing managed IT support for manufacturing technology platforms
Evaluate your manufacturing systems strategy today. Call Preferred Data Corporation at (336) 886-3282 or request a manufacturing technology consultation. We will help you determine whether ERP, MES, or both is the right path for your North Carolina manufacturing operation.