How to achieve maximum utilization of production capacities?

How to achieve maximum utilization of production capacities?

Every day we witness changes in the way we design, construct and manufacture new products. We work in a multidisciplinary environment, knowledge and know-how are increasingly valued, and customers demand sustainable products and solutions. If we add to this the need for higher quality products produced in a shorter time and at a lower cost, it is also logical that we demand more from the software. Therefore, we need powerful solutions that help us to be competitive, reduce the possibility of errors at all stages of development and production, and at the same time enable communication between different departments, with suppliers and customers.

Many companies face limitations in planning more complex production processes. Have you considered that a digital model of your production would help you with an individual and holistic view, as it connects machines, workers, tools and processes, considering their limitations? Do you want the production plan to be created automatically on the basis of orders and to enable the optimization of plans, while at the same time creating different scenarios in just a few minutes? Well, let's start with the plan.

Every production environment needs a plan for its operation, which must be made on several levels, both at the level of sales and at the level of management, planning and scheduling of production. Also considering time frames, the production plan must cover the long, medium and short term.

Most planners face a difficult task when they are planning production: to create an optimal production plan in order to achieve maximum utilization of production capacity, shorten flow times, coordinated material flow, minimum stocks and good plan stability. At the end of the day, the planner wants to have complete control over the plan and ensure a high level of delivery deadlines. Also, most manufacturing companies still use Excel spreadsheets to plan production, which are usually based on projected capacity, production time, and workloads. Because we know that production is dynamic and that real-time data is key to responding to changing opportunities and needs, we offer you a solution for advanced production planning and scheduling. Dassault Systemes' DELMIA Advanced Planning and Scheduling (APS) solution eliminates the limitations of production planning with Excel spreadsheets and provides a single real-time data source that can be accessed by anyone involved in production planning and has an overview of the actual state of production.

DELMIA Ortems software has more than 4,000 users, mainly in North America and Western Europe, and has been at the top of S&OP (Sales & Operations Planning) solutions for more than 30 years.

The best effect of using the APS solution is shown in complex production environments with many products and semi-finished products, complex multi-level bill of materials and a large amount of machines and people. Benefits are also felt i less complex production environments, as DELMIA Ortems enables fast response and automation to changes in production. It also offers the ability to customize the functionality to your needs or your environment, as you can easily turn the functionality on or off as needed.

The main benefits offered by the DELMIA Ortems software solution are:

• Reducing the stock of raw materials and necessary materials

Synchronization of raw materials and required materials during procurement and production, considering all restrictions on the production capacity of machines.

• Shortening production time

Synchronization of all necessary operations for the production of the final product and all necessary semi-finished products. As a result, the waiting time of the machine is shortened and the lack of parts is prevented.

• Meeting delivery deadlines

A complete overview of the plan and realistic deadlines, the possibility of active decision-making and setting priorities.

• Increasing the flow and utilization of machinery and workers

Inspection and management of machine and manpower loads and optimization of tool changes.

• Save time and better collaborate and share information within the organization

Digital transformation of production planning - replacement of outdated planning methods based on spreadsheets, macros and labels with advanced software solutions.

The implementation of Ortems software takes about four to six months, depending on the size of the company and the complexity of production. For the successful implementation and integration of all data, it is good that the company has implemented an ERP system (Enterprise Resource Planning) and possibly also MES (Manufacturing Execution System). DELMIA Ortems can connect to existing systems via its communication interfaces and draw from them the data it needs (customer orders, work orders, purchases, planned and unplanned outages,…).

Picture: Display of machine load in the time scale and work operations

The use of APS systems is expected to increase in the future as more and more companies start investing in the benefits of digital transformation. Companies have realized that the benefits of optimizing business and production processes, sales and distribution are critical to a company’s successful growth.

Let us not forget that efficient data collection, processing and visualization in the company, development of processes and digital solutions to support business and production, introduction of digital business models, development of digital staff and digital jobs, development of digital culture are basic building blocks of successful digital transformation.