Project Focus

Planning & Scheduling
Operational Excellence
Process Automation

Engagement Timeline

2-week Diagnostic
10-week Project

Keywords

Performance 4.0
Optimization

THE OPPORTUNITES

The client needed to optimize the shop floor schedules across three different production processes summing up more than more than 30 machines.

Process wise, roles & responsibilities were lose with multiple daily changes to production schedules contributed to low equipment overall efficiency (OEE) and longer lead times.

The solution must accommodate customer driven business rules & various constraints inherent to the production process & machinery.

The context is a quite profitable Tier 1 manufacturing plant for the Pulp & Paper industry.

Operational performance needed a level-up in monitoring and control of execution and development of critical management tools.

Manual, Excel & paper based business process.

Scheduling was people-driven,  not system-driven. 

in Total Cycle Time
- 0 %

Machine Sequencing Mathematical Optimization Using Python

APROACH AND OUTCOMES

Project focused on Operational Planning & Scheduling, Industry 4.0 & Optimization

OPERATIONAL PLANNING & SCHEDULING

Implementation of Master Plan to match demand & capacity based on mix.

Redefinition of high-level & detailed Operational Planning process from monthly view to daily dispatching.

Formalized Roles & Responsibilities (RACI).

Dispatching process: Definition of daily/shift deliverables at WO level.

INDUSTRY 4.0 & OPTIMIZATION

Integration of Business Rules & Constraints,accommodating all the usability requirements demanded by stakeholders.

Mapping of inputs and parameters impacting an optimal sequencing: a system-driven approach.

Mathematical algorithm to optimize sequencing, resulting in 5% production time improvement and 12% set up time reduction.

Automated reporting integrated with BI tool.