“We didn’t have process owners.
We didn’t have flow diagrams.
We didn’t even know where to start.
But the MES rollout had already begun.”
The Reality: No Process Owners, No Documentation
When I was tasked to define the MES requirements for our end to end production (From Subassembly to Final Packing), I wasn’t handed a neat document or a RACI chart. I was handed chaos.
There were:
- No clear process owners
- No standard work documentation
- No unified view of how the process should work
And yet, we were expected to provide “requirements” for a system that would control our shop floor.
Where We Started — and What Didn’t Work
At first, we relied on high-level assumptions and verbal walk-throughs.
We tried asking department heads what was needed, but many had already left. Others gave vague answers like “just make it track everything.”
We soon realized:
- Asking “What do you need?” wasn’t enough — people didn’t know how to answer
- We couldn’t assume the current screens were complete
- Existing Excel trackers were built out of habit, not design
How We Found Clarity, One Step at a Time
Here’s what actually helped us move forward:
- ✅ Walk the Line — we physically followed the production flow with engineers and operators, station by station.
- ✅ Recreate the Paper Trail — we collected all forms, printouts, labels, and manual logs used in production.
- ✅ Map Roles to Actions — even when process ownership was missing, we asked: “Who does this task now?” and documented from there.
- ✅ Validate with “What-If” Questions — instead of “Is this requirement okay?” we asked:
“What would happen if MES didn’t capture this event?”
That helped uncover hidden logic.“
What I’d Do Differently Next Time
If I were to start over, I would:
- Create visual mockups of expected screens — it helps bring vague requirements to life
- Define critical control points early — even if the whole flow isn’t clear
- Use templates to guide messy interviews — not just blank Excel sheets
- Include quality, traceability, and shop floor usability upfront — not just production counts
Want a Shortcut?
This experience became the foundation for our MES Requirements Checklist (VST-002) —
a simple, structured guide to help others avoid what we went through.
👉 Download the Checklist Free Here (Link to WooCommerce product)
🔗 Related Posts
- What to Do When Your MES Only Speaks Chinese
- From Zero to a Team: Building MES Capability from the Ground Up
Final Thought
You don’t need everything perfectly defined before you start.
But you do need to ask the right questions — even when no one has the answers yet.
“If you’re gathering MES requirements in a factory where chaos is the norm, just know:
It’s normal. It’s possible. And you’re not alone.“