Planning batch production: the example of chocolate

Industrial manufacturing presents companies with numerous challenges, particularly in terms of efficiency, cost optimisation and resource utilisation. Variety production is a tried-and-tested method for specifically improving these aspects. It involves manufacturing products with similar properties and production requirements in successive batches in order to minimise set-up times and material wastage.

Characteristics of unoptimised mass production

In traditional batch production, different products are manufactured one after the other without any specific coordination regarding the similarity of materials or process requirements. This leads to inefficient processes, which result in frequent set-up times, as machines have to be reconfigured for each new product, incurring both time and costs. Furthermore, high material consumption results from non-optimised changes between product types. Longer lead times are also a problem, as delays occur due to waiting times between production batches. To cope with fluctuations in production, unnecessarily high stock levels are required, which in turn necessitates larger buffer stocks.

Variant production: planning products with similar characteristics together

In contrast to uncoordinated batch production, product-type production focuses on grouping together products with similar characteristics. The aim is to enable production runs that are as long as possible without having to change over the machinery. The advantages of this strategy include a reduction in set-up costs due to longer production intervals within a single product type, more efficient use of materials, as there are fewer losses during product changeovers, lower production costs through optimised machine running times and reduced downtime, and greater flexibility, as production planning can be tailored to market demand and seasonal fluctuations.

Chocolate production is an excellent example of optimised product range manufacturing. Here, products with similar recipes and production processes can be grouped into series, thereby making the entire production process more efficient.

Criteria and their optimisation effects

Chocolate products can be grouped according to various criteria. Products with a similar cocoa base, such as milk chocolate, dark chocolate and white chocolate, can be produced together. Varieties containing nuts, dried fruit or caramel should also be produced together to minimise production changeovers. Chocolate bars, chocolate sticks and pralines have different requirements in terms of moulds and packaging, and similar packaging sizes and materials simplify logistics and reduce set-up time. In addition to product characteristics, production-related factors can also be used to optimise production by product type.
In our example of chocolate, for instance, the size or capacity of the available conches can be selected as a planning factor.

Variety-based production enables a number of optimisation benefits to be realised in chocolate production. Cleaning and set-up times are minimised, particularly when switching between products with identical base mixtures. The utilisation of raw materials is optimised, as the same ingredients are processed in large quantities, thereby reducing purchasing costs and minimising material waste. Efficient stock management is made possible by coordinated production plans, enabling raw materials to be ordered and stored in line with demand. Increased machine uptime is achieved through longer production cycles without changeovers, which improves capacity utilisation. Using the approach outlined above – taking the conche size into account in our chocolate example – a possible optimisation measure here is to select the batch size in production as a multiple of the existing conche volume.

Variant production (complex products): chocolates

Whilst simple chocolate bars and tablets have relatively uniform production processes, pralines are an example of a more complex, variant-based production process. Pralines often consist of several layers, fillings and decorations, which requires detailed planning. Nevertheless, efficiency gains can also be achieved here through variant production. Chocolates with similar fillings are produced together, and tempering is optimised by manufacturing chocolates with the same melting temperatures and cooling times in a single batch.

Software-supported production planning

Digital production planning offers significant advantages over manual planning methods. The use of Fekor enables the following optimisations: Automated production planning utilises intelligent algorithms that analyse production capacities and control the optimal production sequence. Real-time monitoring enables the continuous collection of machine and material data to identify bottlenecks at an early stage. Flexibility in the face of production changes is achieved through rapid adjustments without significant changeover losses. The error rate is reduced, as digital planning minimises human planning errors and ensures optimal use of resources.

Fekor is one of our digital solutions that uses modern technologies to optimise production planning in the manufacturing industry. By utilising software solutions, manufacturing processes can be planned and managed more efficiently.

Product group management

A good example of a slightly more specific measure for optimising production with Fekor is product group management. This allows your products to be grouped according to their characteristics during the planning stage and planned collectively. The advantages of this method include optimised stock management, as raw materials and semi-finished products are managed more efficiently. It also enables you to easily reduce capital tied up in stock by avoiding excess inventory, whilst improving production capacity utilisation, as machinery and labour are utilised more evenly.

Conclusion

Variety-based production is an exciting use case for our solutions to optimise production planning, even beyond our example in chocolate production. By strategically grouping similar products together, costs can be reduced, lead times shortened and material wastage minimised. Digital tools such as Fekor and the tetys MES help to further optimise these processes and boost your company’s competitiveness. Those who set the course today will secure a decisive competitive advantage in the long term.