Hybrid MES (Lift & Shift): The Bridge Between On-Prem and Cloud

What is a Hybrid or Lift & Shift MES?

A Hybrid MES – also known as a Cloud-hosted or Lift & Shift MES – describes a transitional architecture between traditional On-Prem systems and modern Cloud-native MES.
It involves running an existing MES application in a cloud environment (e.g., Microsoft Azure or AWS) without major code or structural changes.

In this model, the software remains largely the same but is no longer hosted on local servers. Companies gain partial cloud benefits like scalability and reduced IT load – while maintaining familiar tools and configurations.

You can learn more about the basics of an MES system in our comprehensive MES Guide.

Technical Architecture and Operation

Hybrid MES deployments mirror traditional On-Prem systems:

• centralized application and database servers,

• interfaces to ERP, SCADA, and shopfloor equipment,

• and client terminals for operators and supervisors.

The difference lies in the hosting model:

• The MES application runs on virtual machines (VMs) in a public or private cloud.

• Data acquisition may still occur locally via Edge gateways or OPC UA servers.

• Secure VPN or API tunnels connect on-site equipment with the cloud instance.

Advantages of a Hybrid MES

1. Lower IT burden
Hardware procurement, backups, and maintenance are reduced. Many operational tasks shift to the cloud provider.

2. Faster scalability
New production lines or sites can be added by deploying extra VMs rather than new physical servers.

3. Gradual cloud adoption
A Hybrid model allows organizations to test cloud operations before fully replacing legacy MES systems.

4. Investment protection
Existing MES software (e.g., Siemens Opcenter, MPDV Hydra, Apriso) remains usable, avoiding the need for immediate re-implementation.

Limitations and Challenges

Despite its benefits, a Hybrid MES is not a true cloud-native system:

• Legacy architecture: still monolithic, limited flexibility.

• Mixed CAPEX/OPEX model: license fees persist, plus hosting costs.

• Limited elasticity: scaling is manual, not dynamic.

• Integration effort: APIs often lack modern, event-driven design.

• Complex data governance: data spread across local and cloud layers.

According to IoT Analytics (2024), over 40 % of MES installations currently running On-Prem will move to Hybrid hosting within three years—typically as an intermediate step before adopting fully cloud-native MES.

Typical Use Cases

• Conservative IT strategies seeking minimal risk cloud trials.

• Multi-site operations with mixed infrastructure maturity.

• Phased migrations, where ERP is already cloud-based.

• Pilot projects evaluating SaaS feasibility.

Example:
An automotive supplier operates its legacy MES on Azure VMs.
Machine data is collected locally through OPC UA gateways, while dashboards and KPIs run in the cloud—creating a hybrid environment that balances stability and modernization.

Comparison: On-Prem, Hybrid, and Cloud-Native MES

Conclusion

A Hybrid MES offers a transitional bridge for manufacturers moving from legacy On-Prem infrastructures toward cloud-based operations.
It reduces IT overhead and accelerates rollout but does not deliver the full agility or flexibility of cloud-native MES.
Forward-looking companies use the Hybrid approach as a stepping stone—modernizing infrastructure, collecting migration experience, and preparing data models for the next generation of MES.