-22%
reduction in total cycle time
Project objective: Optimize planning across three production processes (more than 30 machines)
Results
Context and challenge
A profitable, world-reference Pulp & Paper plant that needed to optimize production planning across three distinct processes, with more than 30 machines. Poorly defined roles and responsibilities and excessive daily changes to plans resulted in low OEE and long execution lead times.
Approach and impact
Operational planning and sequencing
A Master Plan to match capacity to demand considering the mix; evolution from a monthly view to daily distribution; a reorganized RACI; dispatching with daily deliverables per station and per employee.
Data and optimization
Integration of operational constraints and rules (including ergonomics); mapping of the parameters that impact sequencing; automated BI reports; a mathematical sequencing-optimization algorithm in Python.
*Selected project result. Gains vary depending on context, maturity and scope.