{"id":33850,"date":"2026-09-29T10:00:00","date_gmt":"2026-09-29T09:00:00","guid":{"rendered":"https:\/\/www.engineernewsnetwork.com\/blog\/?p=33850"},"modified":"2026-09-24T17:34:36","modified_gmt":"2026-09-24T16:34:36","slug":"material-synchronisation-across-plants-how-mom-closes-the-visibility-gap","status":"publish","type":"post","link":"https:\/\/www.engineernewsnetwork.com\/blog\/material-synchronisation-across-plants-how-mom-closes-the-visibility-gap\/","title":{"rendered":"Material synchronisation across plants: how MOM closes the visibility gap"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\"><strong>Mike Bradford looks at the importance of Manufacturing Operations Management on closing the visibility gap across different plants. He explores the following areas in more depth: how mid-tier manufacturers can achieve material synchronisation without a huge amount of complexity; how and why cross-facility material visibility breaks down in multi-site manufacturing; what supply chain pressures make material sychronisation urgent for manufacturers in today&#8217;s world. Supply chain pressures are increasing the need for synchronisation, particularly tariff volatility, rising inventory costs and workforce shortages<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A production line in Juarez stops because a composite batch that left the curing facility in Salt Lake City has not arrived. The batch shipped on time. The carrier confirmed delivery. But the material never reached the plant floor because the consumption forecast was not updated after a customer accelerated their order by two weeks. The material is sitting in a warehouse 40 miles away, allocated to an order that will not run for another month.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This is not a logistics failure. It is a visibility failure. And it is the kind of problem that a\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/manufacturing-operations\/manufacturing-execution-system\" target=\"_blank\" rel=\"noopener\"><strong>manufacturing execution system (MES)<\/strong><\/a>\u00a0controlling production at a single plant was never designed to solve. MES tracks what\u2019s happening in production at a single plant. It doesn\u2019t know what\u2019s happening with inventory at the five other facilities competing for the same materials. That gap between plant-level execution and network-level production and material co-ordination is one of the places where\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/manufacturing-operations\/manufacturing-operations-management\" target=\"_blank\" rel=\"noopener\"><strong>manufacturing operations management (MOM)<\/strong><\/a>\u00a0earns its value.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Only\u00a0<strong><a href=\"https:\/\/procurementtactics.com\/supply-chain-statistics\/\" target=\"_blank\" rel=\"noopener\">6% of businesses report full supply chain visibility<\/a><\/strong>, according to Procurement Tactics.<strong>\u00a0<a href=\"https:\/\/www.mckinsey.com\/capabilities\/operations\/our-insights\/supply-chain-risk-survey\" target=\"_blank\" rel=\"noopener\">McKinsey\u2019s 2025 supply chain risk survey<\/a><\/strong>\u00a0confirmed most companies understand their supply chain risks only up to tier one. That\u2019s the default condition for most multi-plant operations.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Why does cross-facility material visibility break down in multi-site manufacturing?<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The core problem is architectural. Most manufacturers built their execution systems one plant at a time. Each facility runs its own MES instance with its own inventory records (typically in ERP or a separate WMS system), its own material call logic and its own view of what\u2019s available. When procurement, production planning and warehouse management operate in separate systems at separate sites, reconciling material positions requires manual effort that introduces both delays and errors.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Consider what happens when a supplier changes a lead time or a customer revises an order quantity. In a fragmented environment, planners at each plant interpret that change independently. One facility stockpiles material as a buffer. Another releases material already committed to a different production run. A third doesn\u2019t receive the update until the following week\u2019s planning cycle. The result is conflicting decisions made on conflicting data, each one rational in isolation and collectively destructive.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">As Mike Bradford, Business Development Director for\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/apriso\" target=\"_blank\" rel=\"noopener\"><strong>DELMIA Apriso<\/strong><\/a>\u00a0at Dassault Syst\u00e8mes, has emphasised across industry discussions: MOM does not replace MES or ERP. It connects and extends them. When a supplier issue surfaces or a substitute material gets approved, the change is recorded once and propagated to every facility instantly. That\u2019s the architectural shift that turns reactive scrambling into co-ordinated response. A MOM platform makes cross-plant alignment its central purpose.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>What supply chain pressures make material synchronisation urgent for manufacturers?<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The MOM software market is growing because manufacturers are learning these lessons the hard way.\u00a0<a href=\"https:\/\/www.imarcgroup.com\/manufacturing-operations-management-software-market\" target=\"_blank\" rel=\"noopener\"><strong>IMARC Group<\/strong><\/a>\u00a0valued the global MOM software market at $13.7 billion in 2025, projecting a compound annual growth rate of 7.82% through 2034.<strong>\u00a0<a href=\"https:\/\/www.grandviewresearch.com\/industry-analysis\/manufacturing-operations-management-software-market-report\">Grand View Research<\/a><\/strong>\u00a0pegged the market even higher, estimating $17.46 billion in 2024 and forecasting growth to $76.71 billion by 2033 at a 19.1% CAGR. Regardless of which estimate you prefer, the trajectory is unmistakable: manufacturers are investing in operational orchestration, not just execution tracking.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">There are three converging pressures explain the urgency:<\/p>\n\n\n\n<ol start=\"1\" class=\"wp-block-list\">\n<li><strong>Tariff volatility is structural, not temporary.<\/strong>\u00a0In 2025, U.S. tariffs on steel and aluminum doubled to 50%, reshaping global trade flows across automotive, construction and general manufacturing.\u00a0<a href=\"https:\/\/www.deloitte.com\/us\/en\/insights\/industry\/manufacturing-industrial-products\/manufacturing-industry-outlook.html\" target=\"_blank\" rel=\"noopener\"><strong>Deloitte reported<\/strong><\/a>\u00a0that 73% of U.S. manufacturers cited trade uncertainties as a top business challenge in the first quarter of 2025, up sharply from 37% just two quarters prior.\u00a0<a href=\"https:\/\/www.mckinsey.com\/capabilities\/operations\/our-insights\/supply-chain-risk-survey\" target=\"_blank\" rel=\"noopener\"><strong>McKinsey\u2019s risk pulse survey<\/strong><\/a>\u00a0found that 45% of companies facing tariff impacts were increasing inventories, 39% were pursuing dual sourcing and 33% were developing nearshoring plans. Every one of those responses changes material flows across multiple facilities. You need a platform that propagates adjustments across the network simultaneously.<\/li>\n\n\n\n<li><strong>Inventory carrying costs punish poor synchronisation.<\/strong>\u00a0When plants can\u2019t see each other\u2019s material positions, the natural response is to overbuild safety stock at every location. That ties up working capital, consumes warehouse capacity and still doesn\u2019t prevent stockouts because the surplus is never where you actually need it. A synchronised MOM platform replaces guesswork with real-time material positions across every facility, enabling leaner inventory without sacrificing delivery performance.<\/li>\n\n\n\n<li><strong>Workforce constraints amplify every co-ordination failure.<\/strong>\u00a0<a href=\"https:\/\/www2.deloitte.com\/us\/en\/pages\/about-deloitte\/articles\/press-releases\/us-manufacturing-could-need-new-employees-by-2033.html\" target=\"_blank\" rel=\"noopener\"><strong>Deloitte projects<\/strong><\/a>\u00a0the manufacturing sector will require approximately 3.8 million new employees between 2024 and 2033, with roughly half of those positions at risk of remaining unfilled. When experienced planners and material co-ordinators retire, you can\u2019t replace their institutional knowledge of which plants share which material pools. MOM platforms capture that knowledge as digital logic that executes consistently regardless of who is running the planning desk.<\/li>\n<\/ol>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>What do real-time synchronised material operations look like with enterprise MOM?<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">A unified MES\/MOM platform like\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/apriso\" target=\"_blank\" rel=\"noopener\"><strong>DELMIA Apriso<\/strong><\/a>\u00a0operates as a living execution backbone for global manufacturers. Bills of materials, routing logic, quality plans and material allocation rules reside in a single repository. Updates occur once and flow automatically to every site. When a shipment is delayed, production schedules and work instructions adjust across affected facilities in real time, preventing bottlenecks from cascading. When a substitute material gets approved, every plant sees the updated specification simultaneously.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Engineering or continuous improvement teams design a global process template representing the best-known way to execute a particular operation. DELMIA Apriso propagates that template to every relevant site. Each plant configures approved local variations for equipment models, regulatory requirements or material grades, but the core process and material specifications stay governed centrally. Embedded analytics combine production, supply and quality indicators in real-time dashboards, flagging disruptions before they fully materialise.\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/virtual-twin-manufacturing\" target=\"_blank\" rel=\"noopener\"><strong>Virtual twin technology<\/strong><\/a>\u00a0lets manufacturers simulate alternative material flows and sourcing scenarios before committing capital.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>How can mid-tier manufacturers achieve material synchronisation without enterprise complexity?<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Material synchronisation is sometimes seen as an enterprise-only conversation. It shouldn\u2019t be. Mid-tier manufacturers face the same co-ordination challenges with thinner margins. The shift from fragmented MES to unified MOM mirrors a journey many already understand: moving from QuickBooks-level tools to integrated\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/manufacturing-operations\/enterprise-resource-planning\"><strong>ERP<\/strong><\/a>. The same logic applies on the shop floor. You outgrow point solutions when you need consistent material data across facilities to make confident decisions under pressure.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Modern systems provide a practical MES entry point for manufacturers scaling beyond basic MES. It proves that material synchronisation is accessible to mid-tier organisations without enterprise-scale complexity. Configurability rather than customisation is the key architectural principle, the same principle that allows operations to scale without accumulating technical debt.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Why synchronised material operations turn supply chain  visibility into competitive advantage<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Material synchronisation across plants is not a feature request. It is a structural requirement for any manufacturer running more than one facility in a volatile supply chain environment. MES gives you control of each shop floor. MOM gives you command of how materials move across the network. In an operating environment where only 6% of companies have full supply chain visibility and 73% of U.S. manufacturers cite trade uncertainty as a top challenge, the question isn\u2019t whether to invest in synchronised operations. It is whether you invest before the next disruption reveals what your visibility gaps cost you.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Manufacturing will not slow down for disconnected systems. Companies closing their material visibility gaps today are converting operational co-ordination into competitive advantage. Those still reconciling spreadsheets across plants face an increasingly steep climb as synchronised competitors pull further ahead.<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><a href=\"https:\/\/www.engineernewsnetwork.com\/blog\/wp-content\/uploads\/2026\/09\/Mike-Bradford-4.jpg\"><img loading=\"lazy\" decoding=\"async\" width=\"240\" height=\"240\" src=\"https:\/\/www.engineernewsnetwork.com\/blog\/wp-content\/uploads\/2026\/09\/Mike-Bradford-4.jpg\" alt=\"\" class=\"wp-image-33851\" srcset=\"https:\/\/www.engineernewsnetwork.com\/blog\/wp-content\/uploads\/2026\/09\/Mike-Bradford-4.jpg 240w, https:\/\/www.engineernewsnetwork.com\/blog\/wp-content\/uploads\/2026\/09\/Mike-Bradford-4-150x150.jpg 150w\" sizes=\"auto, (max-width: 240px) 100vw, 240px\" \/><\/a><figcaption class=\"wp-element-caption\"><em>Mike Bradford, Business Development Director at DELMIA<\/em><\/figcaption><\/figure>\n<\/div>\n\n\n<p class=\"wp-block-paragraph\"><strong>Case study: how Hexcel achieved global material synchronisation with MOM<\/strong><\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><a href=\"https:\/\/www.3ds.com\/insights\/customer-stories\/hexcel\" type=\"link\" id=\"https:\/\/www.3ds.com\/insights\/customer-stories\/hexcel\"><strong>Hexcel<\/strong><\/a><strong>,<\/strong> a world leader in advanced composite materials for commercial aerospace, space and defence, provides a concrete example. The company operates a vertically integrated manufacturing network where material flows from fiber production through resin formulation, prepreg layup, and final curing across multiple sites. Getting the right composite materials to the right facility at the right time is not a convenience. It is the difference between meeting aerospace delivery schedules and missing them.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Hexcel deployed\u00a0<a href=\"https:\/\/www.3ds.com\/products\/delmia\/apriso\" target=\"_blank\" rel=\"noopener\"><strong>DELMIA Apriso<\/strong><\/a>\u00a0as a unified MOM platform across its global manufacturing footprint, replacing the patchwork of plant-specific systems that had previously governed shop-floor execution. The shift gave every facility, from fiber production through final curing, a shared definition of how materials move, how operations are validated and how data is captured. As Random Kiser, Director, IT Manufacturing Systems, described the impact: \u201c[Regarding DELMIA Apriso] it is a common entry point for all of our operations personnel, all of our factories around the world. It is very easy from an IT perspective, to support, because it is just one platform to deal with instead of multiple platforms. It is a great system because we have all of our data in one place in exactly the same format for our teams to analyse.\u201d<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">That single-platform foundation is what makes material synchronisation possible across a vertically integrated network. When every plant runs the same execution logic, a change in material specification, a substitution approval or a quality update propagates instantly to every facility that needs it. The combination of consistent process execution and unified data gives Hexcel the network-wide visibility that fragmented, plant-by-plant systems cannot provide. Every operator, engineer and analyst across the global footprint is working from the same source of truth, in the same format, at the same time.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Mike Bradford is Business Development Director for<strong> <a href=\"https:\/\/www.3ds.com\/products\/delmia\">DELMIA<\/a><\/strong>.<\/p>\n","protected":false},"excerpt":{"rendered":"<p>Mike Bradford looks at the importance of Manufacturing Operations Management on closing the visibility gap across different plants. He explores the following areas in more depth: how mid-tier manufacturers can achieve material synchronisation without a huge amount of complexity; how and why cross-facility material visibility breaks down in multi-site manufacturing; what supply chain pressures make &hellip;<\/p>\n","protected":false},"author":1,"featured_media":0,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[199],"tags":[13123,14002,15436,15627,15626],"class_list":["post-33850","post","type-post","status-publish","format-standard","","category-news-views-and-opinion","tag-delmia","tag-delmia-apriso","tag-hexcel","tag-manufacturing-execution-system-mes","tag-manufacturing-operations-management-mom"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Material synchronisation across plants: how MOM closes the visibility gap - Engineer News Network<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.engineernewsnetwork.com\/blog\/material-synchronisation-across-plants-how-mom-closes-the-visibility-gap\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Material synchronisation across plants: how MOM closes the visibility gap - Engineer News Network\" \/>\n<meta property=\"og:description\" content=\"Mike Bradford looks at the importance of Manufacturing Operations Management on closing the visibility gap across different plants. 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