Planning & Scheduling Operational Excellence Process Automation
2-week Diagnostic 10-week Project
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.
Machine Sequencing Mathematical Optimization Using Python
APROACH AND OUTCOMES
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.