Mitarbeiter bei der Montage einer Maschine

Assembly planning

Assembly planning often causes problems in terms of scheduling, both in component and machine and systems engineering. Missing parts, highly-individualized units and growing parts lists often prevent on-time planning. In addition, there are often a lot of customer-specific changes.


The emergency is routine in production: the assembly is threatening to stagnate.... the production worker starts with a list of missing parts in their hand.

The complex task of assembly planning is to monitor the production and procurement processes so that all necessary parts, materials and resources are available at the start of assembly. In addition to economic efficiency, there should also be a high degree of flexibility in the processes involved - be it for a fixed-station assembly system, synchronized flow or “one-piece-flow” assembly. In order to achieve these goals and offer strong and profitable solutions as well as a reliable partner, intelligent production planning is indispensable.

Solution FELIOS Features

With FELIOS, the work, procurement and provisioning processes can be optimally synchronized for assembly in order to not delay the assembly  start and consequently the customer delivery date. Special features ensure a smooth assembly process:

  • Special planning function

    Dynamic and flexible inflow of parts and components for assembly.

  • Order scheduling against limited capacities

    Optimization of assembly with target parameters for adherence to schedules and utilization.

  • Early warning system

    Early detection of critical parts leads to an on-schedule assembly.

  • Good visualization

    All information on the planning situation is presented clearly and attractively.


By mapping the complex manufacturing and procurement processes in production, FELIOS ensures that all necessary parts are available at the beginning of assembly. You can also expect this from FELIOS:

  • Reduction of missing parts

    Massively defused missing parts problem in the assemblies.

  • Increased on-time delivery

    Reliable date statements to customers can be made.

  • Reduction of the control effort

    Optimized control and planning leads to less effort despite increasing order volumes.

  • Cost reduction

    Improved workflows and fewer shifts reduce assembly costs.

  • Revaluation of jobs

    Production workers gain time for further development of other work processes.

Reduction of missing parts

Reduction of missing parts in the fixed station assembly

With conventional ERP systems, parts lists are represented so that all items must be available at the start of assembly. In the assembly process, which is often prolonged over several days and weeks, this is not necessary for many parts. They can also increase later. With FELIOS you can plan flexibly - without having to change the processes in the ERP system.

FELIOS constantly checks the dates of receipts, which are stored in the ERP. In this way, effects on collective orders are already visible for a long time in advance. To what extent an impending missing part is "operationally" critical at the start of assembly is evaluated by the planner or solved earlier. In this way, the assemblers know what the situation will look like at the start of assembly.

Workforce scheduling

Workforce scheduling

With the FELIOS employee resource planning system, various employees can be optimally divided up according to their ability profile into the various work processes involved in the assembly. This results in the best possible utilization of personnel capacities. The rolling specification of a feasible, synchronized worklist for each resource also creates a material flow optimization. The worklist deliberately leaves room for a situationally different sequence planning at each workstation by the foremen or planners.


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