Manufacturing Execution Systems Transform Traditional Factories One Problem at a Time

A Midwest RV accessory manufacturer embraces SaaS MES innovation.

The vast majority of U.S. factories still rely heavily on traditional pen and paper processes. With more than 90 percent of factories yet to digitize, production can be adversely affected by labor shortages. However, Elkhart, Ind.-based recreational vehicle accessory manufacturer MORryde took the digital route with Pico MES, an innovative tech solution developed by a veteran of Tesla and GM, and it shows how manufacturing execution systems can make the difference.

In October, Pico MES shared new data indicating that its SaaS technology has enabled factory workers at various levels to amplify their production capacity by 50 percent, while eliminating expensive errors. MORryde is one success story illustrating Pico MES’ compelling approach.

MORryde is a family-owned RV and auto product manufacturer, which abandoned its antiquated processes and transitioned into the digital age by integrating Pico MES’s software. The transformation was profound. With Pico’s SaaS platform, MORryde transitioned over 500 paper-based processes to a digital format, delivered 2,400 error-free chassis to customers, and achieved 100 percent production quality assurance for all their end-products.

Such improvements not only boost efficiency but also ensure a level of precision and quality assurance previously unattainable with manual methods. Ryan Kuhlenbeck, Pico MES CEO, is behind the efforts to develop technological answers tailored to the often-overlooked mid-size factories, which constitute over 98 percent of the U.S. industry. His goal is to reshore jobs, bolster local economies and herald a new era of manufacturing in America.

“What we see in the industry more than anything else is a ‘death by a thousand cuts’ struggle,” said Kuhlenbeck. His observation stems from the myriad challenges smaller factories face—from the critical torque issues faced by companies like MORryde to the labor transition problems that come with constantly evolving products.

Kuhlenbeck explained that many midsize manufacturing challenges aren’t singularly significant enough to warrant immediate solutions. However, with the right approach, they can be methodically addressed. “What we’re trying to solve with companies like MORryde is to take a first step. Pick a problem, even if it’s a 1 percent annoyance, but do it in a way where you have access to other solutions.”

Pico MES’s methodology is to streamline integration and minimize costs. Their model is built on accessibility, with Kuhlenbeck emphasizing a “no-code” approach. “The only thing we need to set up the torque tool is its IP address. You go and tell it what torque value and bang, you’re done.”

Kuhlenbeck’s own journey reflects the evolution of manufacturing technology. After working at GM and Tesla, he gained insights into the barriers that midsize factories face. Traditional systems require months or even years to set up, often involving prohibitive costs. Pico MES is a game-changer in this regard. With trials starting almost immediately, their focus is on rapid integration and user-friendliness.

“We want it to feel as easy to use the first time as you use your smartphone or a laptop in college,” Kuhlenbeck explained. And with their pricing model designed for flexibility and affordability, Pico MES is paving the way for a broader adoption across the manufacturing sector.

MORryde illustrates the transformative potential of this software-driven approach. By seamlessly bridging their ERP with Pico MES, they’ve achieved integrated, efficient production across their factory floors.

As U.S. factories grapple with the challenges of modern production, partnerships like MORryde and Pico MES put a spotlight on options for improving operations. Kuhlenbeck’s vision, firmly rooted in reshoring jobs and revitalizing local economies, paints a hopeful picture of an American manufacturing renaissance.

Even slight improvements can have an exponential effect on overall productivity—minuscule gains, when accumulated, can result in substantial improvements. This is particularly relevant in light of studies that show the U.S. lagging in productivity, despite being at the forefront of technological invention.

One of the primary challenges seems to be the lack of interconnected systems, which would allow for the seamless deployment of various technological solutions. Pico addresses this issue by offering multiple solutions that address diverse challenges for various industries including automotive, aerospace, defense, industrial and semiconductor. In such industries, safety and precision are paramount, and often deal with intricate and multifaceted machinery.

Given the technological pivot towards increased reliance on chips and semiconductors, there’s a growing need for equipment that supports production. The intricate and customized nature of this equipment makes efficient production and documentation vital.

A MORryde employee using the Pico MES platform. (Image: Pico MES.)

A MORryde employee using the Pico MES platform. (Image: Pico MES.)

The stakes are high when it comes to productivity lapses. In industries such as semiconductor manufacturing, even minor mishaps can have billion-dollar implications, as the last thing companies want is to repair equipment inside a costly clean room.

The crux of the matter is simple: factories have been operating in certain set ways for years, and the shift to a digital future is not an easy one. However, when one takes a closer look, it’s evident that this transformation is not just about the application of technology but also about the mindset.

Kuhlenbeck compared the transition to home improvement. “Think about how shows like ‘This Old House’ make people feel comfortable with renovations. The more discussion there is on these topics, the more we can help tie it all together. So, when you do want to use advanced systems, you don’t have to do any of the IT work,” he said.

Much like the gradual revamping of a home, factories can start with what they are comfortable with—the traditional pen and paper—and gradually incorporate digital tools. With proper guidance, the transition can be made smoother, eliminating the fear factor associated with new technologies.

This transition from traditional to digital is a phased approach, “You have two choices: either there’s a factory with engineers, which is rare, or buy it as a service,” said Kuhlenbeck. “Our goal is to start you with paper and pencil, converting to digital work instructions and just barcode readers, but you’re exposed now to things like those software sets.” This allows companies to witness firsthand the tangible benefits of incremental digital adoption, from error reduction to efficiency improvement.

“I look back a year later and see this complete digital backbone with no failures on critical aspects, like torques for vehicles,” Kuhlenbeck reflected, embracing small changes that accumulate to drive significant impact over time. “It’s these subtle things that make everything a little bit easier.”

He added that many factories have a hard time even understanding the ‘death by a thousand cuts’ concept, but they’ll see it in their output variation, or they’ll see it in their profit margins.

“If your only solution is to ask people never to make a mistake again, good luck,” Kuhlenbeck said. It underscores the imperative for modern factories to acknowledge the myriad inefficiencies plaguing them and to employ smarter solutions rather than merely seeking a vague sense of perfection.

As technology and digital tools continue to advance, embracing them incrementally and with understanding seems to be the key to a smoother transition and a more efficient future. With the proper application of technology, and the right mindset, U.S factories could grasp a promising new era of production.