5.1 MES Rollout Method (Pilot -> Line -> Factory) + Cutover Checklist

Deploying a new MES or ERP module acts as a transplant of the manufacturing facility's nervous system. A flawed implementation risks stopped production lines, lost traceability, and unrecoverable scrap. Execute the roadmap with precision to validate system logic against physical reality before scaling, ensuring business continuity and data integrity.

The Pilot Phase

Isolate variables by selecting a controlled environment to validate the system under real-world conditions. Restricting the initial scope protects total facility output from unforeseen logic errors.

Pilot Selection Logic

If Line Utilization > 85% OR New Product Introduction (NPI) active → Exclude from scope. High-stress environments mask system bugs with operational noise.
If Line stability is historical (Yield ≥ 98%) AND Operators are Senior → Designate as Pilot. Experienced users distinguish between process errors and system faults quickly.

Execution Scope

Run the new system in parallel with the legacy process only if data synchronization is automated. Otherwise, perform a hard cut-over for the Pilot scope to force reliance on the new logic.

Duration: Minimum 5 production shifts or 1 complete work order cycle (Start to Ship).
Exit Condition: Zero Critical Bugs (Class A) for 48 consecutive hours.

Pro-Tip: Incentivize Pilot operators. They are effectively performing Quality Assurance on the architecture. Treat their feedback as engineering data, not user complaints.

Rollout Strategy

Scale the system only after the Pilot meets all exit criteria. Adopt a staggered approach to manage support bandwidth and mitigate systemic risk.

Expansion Sequence

Phase A (Pilot Expansion): Extend to similar lines/processes. Monitor load balancing on servers.
Phase B (High Mix/Low Volume): Deploy to complex configurations. Verify logic robustness against edge cases.
Phase C (High Volume): Deploy to critical mass production lines.

Go/No-Go Decision Gate

Evaluate Ticket Velocity before authorizing the next phase.

If Ticket Creation Rate > Ticket Resolution Rate → Suspend expansion. The support team is at capacity; scaling further risks operational bottlenecks.
If Critical Issues = 0 AND User Adoption ≥ 95% → Proceed.

Hypercare Period

Hypercare is a temporary state of elevated support and monitoring immediately following Go-Live. Focus resources on rapid stabilization rather than permanent assistance.

Support Architecture

Floor Presence: Station System Engineers physically on the production floor. Visual observation of user interaction reveals friction points that logs miss.
SLA Targets:
- Class A (Line Stop): Response ≤ 10 minutes. Resolution/Workaround ≤ 1 hour.
- Class B (Feature Block): Response ≤ 1 hour.

Hypercare Exit Criteria

Conclude Hypercare only when the system behaves predictably.

Stability: System uptime ≥ 99.9% for 2 weeks.
Autonomy: L1 Support (Helpdesk) resolves ≥ 80% of incoming tickets without Engineering intervention.

Acceptance Criteria (UAT)

Define binary success metrics prior to deployment. Rely on engineering data rather than subjective feedback regarding system speed or feel.

System Performance

Transaction Latency: Scan-to-Response time ≤ 500 ms (Local), ≤ 800 ms (Cloud).
Label Printing: Trigger-to-Print ≤ 2 seconds.

Data Integrity

Traceability: 100% match between Physical vs. Digital inventory count at Go-Live.
Genealogy: 100% parent-child linkage verification for multi-level BOMs.

Pro-Tip: Test the "Unhappy Path." Simulate incorrect barcode scans, network drops, or forced power cycles. The system must retain data integrity during these events to be considered production-ready.

Final Checklist

Category	Metric / Control	Threshold / Rule
Pilot Selection	Yield Requirement	Line Yield ≥ 98% (Stable Process)
Go-Live	Blocker Count	0 Critical (Class A) Bugs
Performance	API Latency	≤ 500 ms avg
Hardware	Peripherals	100% Scanners/Printers validated
Support	Ticket Velocity	Resolution Rate > Creation Rate
Data	Inventory Accuracy	100% Physical/Digital match
Training	User Competency	100% of Shift Leads certified