In modern industry, batch production remains an essential pillar for sectors that require flexibility, quality control and operational efficiency. However, today's challenges - such as changeover times, batch-to-batch cleanups and the need for full traceability - demand a more digital, automated and connected approach.
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In this practical guide, we explore how to optimise the batch production process using methodologies such as SMED, finite planning, and integration with digital systems, such as MES INEXION, which connects planning, maintenance, and traceability in a single operating environment.
Batch production is an industrial manufacturing process in which groups or sets of identical products are produced at the same stage before moving on to the next. Instead of manufacturing a product continuously, it works in "blocks" of production, which offers a balance between efficiency, flexibility and control.
This method remains key, especially in sectors where customisation, quality and demand variability are critical:
Batch production combines the control of discrete manufacturing with the efficiency of continuous processes, allowing rapid adaptation to changes in demand or formulation.
| Feature | Batch Production | Continuous Production |
| Scale | Medium | High |
| Flexibility | High | Low |
| Quality control | In each batch | In-line |
| Cost per unit | Medium | Low |
| Ideal for | Variable or customizable products | Standardized products |
| Example | Food, cosmetics, mechanical parts | Fuels, steel, paper |
In an Industry 4.0 context, batch production has been modernised through automation, digital control, and data analytics, achieving productivity close to that of continuous processes without sacrificing adaptability.
One of the main challenges is the management of changeover times between batches - machine adjustments, cleaning, calibrations or change of formulations.
Every unproductive minute directly impacts operational efficiency and OEE (Overall Equipment Effectiveness), so reducing set-up time is a strategic priority.
Delays between batches or rework due to quality errors increase production costs by up to 12%, especially in regulated industries (such as pharmaceuticals or food) where cleaning and validation are mandatory.
Excess inventory in process (WIP), waiting between phases or communication failures between areas are silent sources of inefficiency.
Lack of visibility into the status of the batch process can lead to late or reactive decisions. Companies that still manage control by paper or Excel are less efficient than those that operate with interconnected digital systems.
That is why automation in production and the integration of MES (Manufacturing Execution System) systems are now essential for competitiveness.
The SMED (Single Minute Exchange of Die) methodology, developed by Shigeo Shingo, aims to reduce changeover times to less than 10 minutes.
This is achieved through standardisation, separation of internal and external tasks, and the use of pre-prepared tools.
Note: In a beverage packaging plant, applying SMED can reduce changeover time between flavours from 45 to 12 minutes, improving OEE by 18%.
Finite scheduling allows optimising the batch production sequence, balancing the workload and avoiding bottlenecks.
Unlike infinite planning, which assumes unlimited equipment and personnel capacity, finite planning takes into account actual plant constraints, such as machine availability, changeover times or scheduled maintenance.
Levelling (Heijunka), on the other hand, distributes production evenly to minimise variability.
Both strategies, combined, reduce waiting times, changeovers and intermediate stock.
A common mistake in batch plants is not synchronising maintenance and cleaning plans with production planning.
Integrating these tasks into the calendar allows taking advantage of scheduled shutdowns and avoiding conflicts between departments.
With the help of the MES INEXION system, this coordination can be automated in real time.
In the era of industrial digitalisation, manual control is no longer viable.
The integration between ERP, MES and traceability systems makes it possible to connect planning (ERP), execution (MES) and on-site monitoring (PLC, SCADA, IoT).
With MES INEXION, companies achieve:
The MES system automatically calculates the actual cost of each batch, combining data on energy consumption, machine times, materials and labour.
This facilitates data-driven decision making (Data-Driven Manufacturing) and allows you to optimise prices, margins and operational efficiency.
See success stories of the MES INEXION system.
Measuring operational efficiency requires a set of KPIs that reflect actual plant performance:
The MES INEXION system automatically calculates these indicators and displays them in real time on visual panels accessible for maintenance, production and quality.
Batch profitability analysis combines cost metrics (energy, materials, time) with efficiency indicators.
In this way, managers can:
Industrial batch production is evolving into an intelligent, traceable and connected model, where finite planning, analytics and automation replace manual control.
Companies that digitise their process using MES systems will gain a clear competitive advantage:
Contact us and discover how to integrate planning, traceability and digital efficiency with MES INEXION.