Insurance can’t fix the gap between Planning and Execution In manufacturing, execution rarely aligns perfectly with the original plan. To deal with this, manufacturers buy what essentially amounts to “insurance policies”. These include everything from longer order lead times and excess inventory to overtime labor and premium freight. The general idea is to absorb the …
Case Study Summary Gulistan Carpet, a leading carpet manufacturer based in North Carolina, has been producing high-quality residential and commercial carpets for nearly a century. The company faced significant challenges managing complex production operations across 2,000 different colors and 70 styles while serving 4,000 retailers nationwide, resulting in lengthy three-week lead times and high inventory …
About Martin’s Rubber Martin’s Rubber is a specialist manufacturer of elastomeric products including seals, gaskets and bespoke rubber mouldings for engineers and manufacturers worldwide. The business was founded over 150 years ago in Southampton, UK, where it still has its headquarters. The Challenge – Hundreds of Different Parts with Variable Batch Runs and Lead Times …
Automotive APS Problem Scheduling a stamping press operation can be a complex and time-consuming task. For example, an in-house stamping plant for an auto OEM consists of two press lines, with 34 dies that produce about 80 distinct parts. These parts are stored on over 250 racks of 37 distinct rack types that hold inventories …
Automotive Production Scheduling Challenge A major automotive OEM was facing material shortages from suppliers and this was exacerbating production problems. This automotive manufacturer had already implemented Eyelit Technologies’ APS asked for help managing supply chain instability. Material shortages from suppliers were causing production problems. Key Takeaways The Order Moves solution from Eyelit Technologies reduces Order to Delivery …
Food & Beverage Plant Background In Planning and Scheduling, the “devil is in the details” – unless all relevant details of the production environment are accurately modeled and solved, the resulting plans and schedules will be sub-optimal, or even unbuildable. A case in point is a Food and Beverage (F&B) plant with a complex production …
Manual Planning & Scheduling Problem: The client faced challenges with their manual planning and scheduling process as component lead times increased and production demand surged. This manual effort became increasingly difficult to manage efficiently, prompting the need for an APS solution to automate and optimize their processes. APS Solution: Using Eyelit Technologies APS, the client …
Why Execution Always Varies from the Plan (and What That Really Means for Manufacturing Systems) Execution always varies from the plan. We know this, we plan for it, and we bake inefficiencies into the planning process to deal with that variability, extended order lead times, safety stock, lower planned machine utilization, overtime, expedited freight, and …
BACKGROUND A major auto OEM was faced with the challenge of replacing its legacy system for order sequencing. With increased complexity due to new models and production mixes, the current solution was not able to perform and solve the OEM’s production challenges. The heuristics-driven competitor was not able to produce a buildable schedule, which was …
We will be discussing the powerful combination of advanced planning, scheduling, and sequencing with a full MES/MOM capability that includes quality, SPC, IOT, special work requests, factory connectivity, factory analytics/insights and ERP/supply chain system integration. As you read this paper, one provocative thought to keep in the back of your mind is related to your …
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