Industrial production planning and control software: buffer management for mid-term scheduling and continuous monitoring. Remove waste and generate business value.
Op.pla is the innovative finite capacity scheduling software for industrial production optimization and planning. Op.pla provides mid-term scheduling, automating day-to-day tasks and giving the user extra time for monitoring and risk mitigation activities.
Op.pla makes it possible to analyse and manage real-world processes constraints and to provide full visibility of order (and/or job) priorities by alerting the user about activities at risk of delay.
Op.pla simplifies and optimises industrial production scheduling using buffer management as a planning and control tool. Op.pla reduces and manages the complexity and uncertainty resulting from the mutual dependency between different production phases, assets and constraints.
- Sales Manager: is provided with information regarding the order and/or job status and will be able to satisfy customers’ requirements about delivery dates;
- Plant Operator: will have complete visibility on priorities between orders and/or jobs through a simple traffic light display, helping to focus on the general overview and on high priority activities.
- Head of Planning and Management: will be able to identify - through daily monitoring of safety buffer consumption - where and when it is necessary to take action to reduce risk in order to reach the business goals. It also helps to understand if the buffer size is actually enough to handle unexpected events, so that it can be promptly adjusted to ensure its protection against unusual occurrences occurring in the operating environment. Op.pla provides complete visibility on actual resources availability and allows to simulate unexpected scenarios.
Op.pla makes it possible to:
REDUCE LEAD TIME AND WIP
Based on a finite capacity optimizer, Op.pla suggests the best sequence for production orders (and/or jobs) according to the "critical chain & buffer management” theory. This approach involves managing a unique time safety buffer to protect the entire work process - i.e. the expected delivery date - appropriately sized according to the critical chain, increasing overall efficiency and reducing the lead time.
The safety buffer makes it possible to disconnect the different production phases of an order and/or a job, reducing the risks associated with the mutual dependency between them and absorbing any critical situations due to unexpected events and the uncertainty occurring during the production and/or the project.
INCREASE ON-TIME DELIVERY
For each optimised order (and/or job), Op.pla automatically calculates the priority of production, in relation to the estimated time to completion and to the residual time in the safety buffer. This information is easily and effectively visualised and made accessible by the user through a traffic light system. Different colours are used to display the chance of each order being late.
The production user will make the daily production schedule according to the priorities suggested by Op.pla and summarise what exactly produced in order to use this information for further optimisation.
PREDICTIVE DATA ANALYSIS
Op.pla enables strategic decisions based on real production and/or project performance and provides simulations to anticipate unexpected scenarios and to react promptly and with intelligence. The "what if" analysis allows to evaluate the impact of unusual events on business KPIs and to forecast future scenarios in order to provide the management with mid- or long-term strategic guidelines.
GENERATION OF CORPORATE VALUE
Op.pla simplifies and objectively formulates the planning strategy by allocating less resources to routine activities and more resources to those tasks that truly have an impact on the final goals. In this way it is possible to gain more time to perform analysis that provides business value and permits a rapid and effective action in case of unusual occurrences and risks affecting objectives. Op.pla makes planning a business asset.
OPTIMIZATION OF INTERNAL WORKING PROCESSES
Op.pla is most effective in make-to-order processes (MTO) and engineering-to-order processes (ETO) where a significant number of orders and/or jobs shares resources where integrated planning across all departments is crucial, from engineering to purchasing and from sales to production.
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Process optimization, steel industryIndustrial production scheduling with Op.pla: an important steel plant, more than 1,200 daily orders to be planned and an extremely diversified product portfolio.
Nesting and logistics, steel industryProduction planning from order to delivery for a company specialized in sheet metal working, the requirement to optimize coil cutting and logistics.