Module D · Production Planning

Finite Capacity.
Infinite Efficiency.

Stop planning in Excel with infinite capacity assumptions. Our AI-driven scheduler respects machine constraints, maintenance windows, and raw material availability to create executable plans.

See Live Scheduler Explore Features
-20%
Changeover Time
99%
Schedule Adherence
Auto
Material Alloc.
APS_Scheduler_View
Live Execution
Resource
08:00 12:00 16:00 20:00
Line A (Pack)
WO-1023: Cola 1.5L
Line B (Fill)
WO-1024: Water 500ml
Mixer 01
Preventive Maint.
Production
Changeover
Maintenance
Optimization: Min. Setup Time

The "Infinite" Trap

  • ERP systems assume infinite capacity, creating unrealistic plans.
  • Manual scheduling in Excel leads to forgotten changeovers.
  • Material shortages are discovered only when production starts.

Constraint-Based APS

  • Plans respect machine limits, labor shifts, and tool availability.
  • Sequence optimization reduces setup time by grouping similar products.
  • MRP is synchronized: No materials = No schedule.

Smart Execution

AI-Driven Factory

AI Job Scoring & Prioritization

Which job should run next? It's not just "First In, First Out". Our AI calculates a composite score for every work order based on Due Date Slack, Customer Tier, Energy Cost, and Material Readiness.

  • Slack Time Analysis: Prioritize jobs at risk of lateness.
  • Customer Tiering: Key Accounts get automatic priority.
  • Sequence Optimization: Boost jobs that share setup attributes.
Job Backlog Ranking
WO-9001 | Retail Giant A
Due: Tomorrow
98.5
AI Score
WO-9005 | Distributor X
Due: In 3 days
72.0
AI Score
WO-9012 | Local Shop
Material Shortage
0.0
Blocked

Integrated MRP & Shortage Alerts

Schedule meets Inventory. Our system "explodes" the BOM (Bill of Materials) for every scheduled job and checks component availability in real-time.

  • Shortage Radar: Visual alerts for missing RM/PM.
  • Dynamic Lead Times: PO recommendations based on actual vendor performance.
  • Alternative BOMs: Suggest substitutes if primary material is out.
Material Coverage Check
Finished Good (Production)
Bottle Pre-form OK (12k in stock)
Label Roll (Brand X) SHORT (-500 units)

Key Outcomes · แบบวัดผลได้

From firefighting to predictable production.

We design measurable KPIs from day one so you can track impact by line, plant, and product family.

Planning Efficiency

-40–60%

Planner time spent on manual Excel re-scheduling.

  • Standardized playbook across lines
  • Auto-sequence by rules instead of gut-feel

Service Level

+10–20 pts

Improvement in OTIF / DIFOT for key customers.

  • Align production with priority orders
  • Early alerts before due date risk

Stability & Loss

-30–50%

Unplanned changeovers, urgent re-runs, and waiting time.

  • Sequence-dependent setup rules
  • Maintenance windows built into plan

Material Shortage

-50–70%

Production stops due to missing RM/PM after go-live.

Plan vs Actual

≤ ±5%

Gap between planned and actual volume by day/line.

Roll-out Speed

4–8 weeks

Typical time to stabilize one plant with templates.

One cockpit for Production & MRP.

Planners don’t have time to jump across 5–6 screens. We unify work orders, capacities, materials, and alerts in a single cockpit.

  • 360° view per line: Orders, changeovers, maintenance, and MRP exceptions in one timeline.
  • Inline actions: Drag & drop jobs, confirm reschedule, trigger rush PO from the same screen.
  • Role-based views: Planner vs. Production Supervisor vs. Material Planner.
Typical result: -30–40% reduction in “screen hopping” time and manual data export/import.
Line Overview – Today Plant KW · Beverage

Jobs Released

36

+12% vs last week

Shortages

3

Click to open MRP radar

Plan vs Actual

96%

Target ≥ 95%

Changeovers

7

Grouped by flavor & pack size

Finite capacity optimization with real plant constraints.

Our engine is built around how factories really run – overlapping operations, shared resources, cleaning cycles, and campaign planning.

Unique Feature

Multi-constraint time buckets

Model machine, labor, tools, and utilities in the same horizon.

Unique Feature

Sequence-dependent setups

Reduce color/flavor/size changes with rule-based campaigns.

Typical result: +5–10% throughput and -15–25% total setup time at line level.
Constraint Summary – Line B (Fill) Feasible
Machine Load (24h) 91% used
Labor Coverage 3 of 3 shifts
Tool / Mold Availability 1 risk
Energy Peak Avoidance 82% off-peak

Sales · Marketing · Production

Close the loop between forecast and real capacity.

Instead of fighting over who is wrong, we show Sales, Marketing, and Production the same truth: what can be produced, when, and with which constraints.

Unique Feature

“What-if” slots by campaign

Simulate campaign uplift and see impact on capacity and RM/PM.

Result: -30–40% ad-hoc urgent campaigns.

Unique Feature

Scenario compare

Compare “Sales preferred” vs “Factory feasible” vs “Cost optimal”.

Result: faster S&OP decision within 1–2 hours instead of days.

Unique Feature

Comment & lock mechanism

Lock confirmed slots and keep track of who changed what and why.

Result: +20–30% reduction in internal disputes and re-approval cycles.

Schedule with cost and energy in mind.

Our AI doesn’t just fill capacity – it can be tuned to minimize overtime, energy peaks, or total production cost.

  • Tariff-aware planning: Shift high-load jobs away from peak tariff windows.
  • Overtime control: Set max OT per shift and auto-balance across lines.
  • Cost-per-unit view: See cost impact for each scenario before approving.
Typical result: -5–10% energy cost for energy-intensive plants and -10–15% overtime cost.
Scenario Cost Comparison Day +1 Horizon
Baseline (current way) 100% cost
AI – cost optimized -8.3%
AI – service prioritized +1.2% cost
Energy peak load (kWh) -12.5%

Multi-Plant · Multi-Country

Built for scale – from pilot line to regional network.

We use templates for process, master data, and KPIs so you can replicate success quickly across plants, countries, and product categories.

Rollout Blueprint

  • Standard template for routing, calendars, and shifts.
  • Checklist for SAP / ERP integration points.

Governance & KPI Pack

  • Standard KPI set: Plan vs Actual, OTIF, changeover, loss time.
  • Weekly S&OP/S&OE report templates.

Impact in Numbers

  • Payback typically within 6–12 months.
  • Common to see 3–5% increase in effective capacity.

SCHEDULING LOGIC & HEURISTICS

Earliest Due Date (EDD)
Shortest Processing Time (SPT)
Critical Ratio (CR)
Theory of Constraints (Drum-Buffer-Rope)
Sequence Dependent Setup

Optimize your shop floor today.

Move from "firefighting" to "orchestrating." Schedule a demo to see how our Finite Scheduler handles your complex constraints.

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