Digital Planning in Manufacturing

Production planning begins where a need is recognised. Whether through a specific customer order, the fulfilment of a minimum stock level or on the basis of long-term sales forecasts - efficient organisation of production processes is crucial in order to optimise costs, avoid bottlenecks and ensure delivery capability.

The ressources

Efficient production planning requires a thorough analysis of the available resources. Firstly, we must ensure that the required raw materials, semi-finished products and individual parts are available, as missing materials inevitably lead to production delays. It is also crucial to optimise the use of machine capacities, whereby maintenance cycles and set-up times must be carefully planned. Specialised tools must not become a bottleneck, so their availability and functionality must be ensured. Finally, the availability of qualified employees is of central importance. Shift schedules, qualifications and experience levels must be taken into account to ensure smooth production.

The product

The characteristics of the product to be manufactured determine the guidelines for planning. Various aspects need to be taken into account. The complexity and multi-stage nature of a product play a role, as simple products with few production steps can be produced more quickly and flexibly than complex assemblies with several intermediate stages. Shelf life is also important, as products such as metal components can be stored easily, while perishable goods require just-in-time production. In addition, sales of a product can fluctuate seasonally, as is the case with winter tyres, for example, and procurement can also be seasonal, as is the case with agricultural products.

Clients

Production planning is influenced by various clients. Customer orders often set tight time frames, as customers expect fast delivery times. Sales plans based on forecasts and long-term planning help to evenly utilise production capacity. To ensure delivery capability, a minimum quantity of a product is often kept in stock, which may be due to high replacement costs, long delivery times or safety requirements.

Digital production planning with modern software tools

A production planning and scheduling system (PPS) is one of the central tools for optimising production processes. It enables the digital mapping, simulation and handling of production and ensures a high level of transparency throughout the entire value chain. Our dedicated software tools - be it FEKOR as a powerful PPS system, our tetysMES with the integrated planning board, or even the combination of both tools - collect and process all production-relevant data and support your users with clear forecasts, analyses and planning. As a result, we ensure significantly more efficient and smooth production processes.

The advantages are manifold. Firstly, we work with you to optimise resource planning by using our tools to show exactly how many raw materials are needed and when. This leads to better order quantity and stock planning. Secondly, a PPS system shortens throughput times, as the production process is optimised and machines and production staff are optimally utilised. Thirdly, it improves delivery reliability, as delivery dates can be realistically predicted and adhered to. Finally, a PPS system reduces production costs, as production is computerised and therefore more efficient.

Interface: from the ERP system to the PPC system and back

A PPS system is usually closely linked to an ERP system (Enterprise Resource Planning). While the ERP system manages commercial data such as orders, invoices and, if necessary, master data, the PPC system takes over operational production planning. Shared master data, especially for materials, machines and personnel, is essential. The quality of this data is crucial for smooth planning and should be checked regularly.

Rough planning and detailed planning

Production planning is divided into two stages. Rough planning creates a long-term overview of production capacities and distributes orders over longer periods of time, taking available resources into account. Detailed planning optimises the sequence of the individual production steps, minimises set-up times and compensates for short-term bottlenecks.

Proactive optimisation

Production planning can be optimised according to various criteria. Cost optimisation is about minimising inventory costs, machine downtimes and overtime, which is achieved through efficient use of resources and sensible batch size planning. Schedule optimisation aims to reduce delivery times by identifying bottlenecks at an early stage, examining alternative production routes and adjusting priorities.

‘...And what are your further plans?’

Modern production planning does not end with machine control. In fact, neighbouring areas such as personnel and maintenance planning are also essential for trouble-free production.

Personnel planning

The availability and qualification of employees plays a central role in production planning. Important aspects include employees' knowledge of machines and tools, as not every employee can operate every machine. Digital planning must therefore take qualifications into account. The availability of employees, influenced by shift schedules, holiday periods and sick leave, also plays a role. Additional qualifications such as driving licences, safety certificates or special further training may be necessary to fulfil certain tasks.

Maintenance planning

Well thought-out maintenance planning helps to avoid unplanned downtime and extend the service life of machines. A PPS system can coordinate maintenance dates with production planning and schedule planned maintenance without disrupting production. Sensors and IoT technologies can detect impending defects at an early stage, enabling predictive maintenance. A well-managed spare parts warehouse also significantly reduces downtimes.

Conclusion

Digital production planning with the help of modern software solutions is an essential building block for efficient manufacturing processes. It enables needs-based, cost-optimised and on-time production. By integrating our products with your surrounding system landscape, we ensure forward-looking personnel and maintenance planning as well as proactive optimisation. This makes your production more transparent, more flexible and more resilient to critical disruptive factors and the challenges of the future. Companies that digitalise their production planning can significantly increase their competitiveness and meet the increasing demands of tomorrow's industry.

Contact us if you would like more in-depth information on this topic! Together, we will find your individual starting points and set about realising your digital potential, in your production planning and beyond.