MES Data Collection – BDE, MDE & Real-Time Production Transparency

Definition

Data collection is the foundation of every Manufacturing Execution System (MES).
It ensures that information from machines, systems, and manual feedback is gathered and consolidated in real time.
According to VDI 5600, this functional area includes machine data collection (MDE), operational data collection (BDE), and the capture of events, downtimes, and process values.

Purpose and Significance

The goal of MES data collection is to create a transparent, objective, and complete picture of production.
Only reliable data allows key performance indicators such as OEE, availability, performance, and quality to be calculated accurately and improved continuously.

A modern MES connects machines, PLCs, sensors, and operators within a consistent data flow — eliminating manual transfer errors and delays.

Key Tasks

• Machine Data Collection (MDE): automatic capture of statuses, downtimes, cycle times, and process values

• Operational Data Collection (BDE): manual or semi-automatic reporting of orders, good/reject quantities, setup and labor times

• Event Recording: documentation of disturbances, alarms, and state changes

• Energy and Process Data Collection: inclusion of consumption and quality parameters

• Time and Shift Assignment: linking events to time frames, lines, orders, and employees

• Data Validation: plausibility checks to ensure data accuracy before analysis

Practical Benefits

• Transparent production: real-time overview of equipment status, performance, and losses

• Data-driven decisions: reliable basis for OEE and KPI analyses

• Less manual effort: automated feedback replaces Excel sheets and paper forms

• Higher efficiency: root-cause analysis of downtimes within minutes

• Seamless integration: BDE and MDE data feed directly into quality, scheduling, and reporting functions

Example from Manufacturing Practice

A plastics manufacturer replaces isolated systems with an integrated MES combining BDE and MDE.
Machine signals are captured automatically, while operators enter quantities and scrap via terminals.
Result: full OEE transparency, 15 % less downtime, and drastically reduced reporting effort.

Integration with Other MES Functions

Data collection provides the foundation for all other MES functions:

• Supplies real-time feedback to scheduling and dispatching

• Delivers process data to quality management

• Connects with material and personnel management

• Feeds KPIs into information management dashboards

This data layer enables truly data-driven decision-making across the entire production process.

Conclusion

MES data collection links machines, people, and systems into a single source of truth.
It creates the basis for transparency, efficiency, and traceability in real time — the essential first step toward digital manufacturing.