Single-item and small-batch production

In order to be a successful single-item and small-batch producer, it is usually no longer sufficient to offer high-quality, specialized products due to increasing market requirements in various industries. Therefore, fast, precise and cost-efficient production in single-item and small-batch manufacturing has become indispensable.

Overview

Single-item and small-batch manufacturing is characterized by special features that can make an optimal production planning difficult. Amongst others these challenges are:

  • Small batches
  • Permanent customer-specific change requests
  • Highly varying manufacturing processes 
  • Short-term delivery bottlenecks in external manufacturing
  • Custom parts
  • Fixed capital through anonymous purchased parts.

Intelligent production planning software supports single-item and small-batch manufacturers by dynamic planning to cope with these requirements and to react flexibly to unpredictable events.

Solution FELIOS Features

Complementing your company´s existing PPS/ERP system, FELIOS optimizes the order execution. The intelligent linkage of orders and assignment of all materials across all scheduling steps prevents bottlenecks and uneven resource utilization. FELIOS offers the following key features:

  • Planning with limited capacities

    Optimal succession of processes taking into account the available capacity.

  • Scenario simulation

    Changes in quantities and dates and their effects on the current order backlog can be analyzed.

  • Automatic and manual planning

    Flexibly adjustable frozen zone, manual fixing and prioritization of entire production orders are available.

  • Setup optimization

    A summary of identical parts is compiled to reduce setup times.

  • Optimized work supply per work station

    Intelligent and coordinated work distribution for individual work stations and machine groups.

  • Identification of bottlenecks

    Practical planning board per work station allows to setup alternatives (alternative work stations, outsourcing, extended workbench).

  • Optimized scheduling and order release

    Proposals for production dates and purchased parts in line with loads and requirements.

  • Analyses, key performance indicators and statistics

    Automated reporting for e.g. orders, suppliers, materials, productivity and fulfillment levels.

Benefits

FELIOS meets all challenges in single-item and small-batch production that conventional PPS/ERP systems ignore. Implementing FELIOS, your company can expect the following advantages:

  • Flexibility

    Synchronous and automatic planning processes increase flexible working required by an individualized production.

  • Better resource utilization

    Material flows are coordinated in order to optimally smoothen load peaks as well as bottlenecks.

  • Cross-departmental transparency

    Central and up-to-date information on the degree of processing and the completion date of all orders.

  • Risk monitoring

    Provides all details on parts that are at risk being late. The user receives solution proposals.

  • Fast simulation

    Various planning scenarios can be carried out in real-time, for example, machine failures or customer inquiries.

  • Production cockpit

    Quick overview of KPIs such as flow rate, residue development, lead times, bottlenecks as well as various target-actual comparisons.

Time is Money

Time is Money

Based on key performance indicators such as residue evaluation, missing parts quotas, lead times, expense factor, flow rate or work-in-progress (WIP), processes can be identified where time or money is wasted. These processes can be optimized with FELIOS. Therefore, process-relevant KPIs are identified and visualized according to the company´s requirements.

An example: The time and effort required to create weekly reports in Excel was reduced from 45 minutes to just 15 seconds for a business user.

Success Story: Neumeister Hydraulik

Success Story: Neumeister Hydraulik

The company "Neumeister Hydraulik" is just one example of successful market-synchronous production. Visible positive effects can be seen in the fact that the order growth could be managed without additional administration.

"FELIOS relieves our planners and dispatchers of 80-90% of annoying routine tasks. Thanks to intelligent planning and transparency, we focuse on minimizing risks in the production process. And if something happens, we make the right decisions quickly. We can handle our strong growth and the necessary flexibility with the same team in our order center." Helmut Wöhr, Technical Manager at Neumeister Hydraulik GmbH.

Intelligent Planning offers High Potentials

Intelligent Planning offers High Potentials

Based on the optimization indicators, INFORM has developed benchmarks with which the individual values and KPIs of the future customer can be compared with those of existing FELIOS applications. The optimization gains that a single-item and small-batch producer can achieve become clear as early as the evaluation phase.

In three steps, we offer interested companies a qualified, KPI-based overview about:

  • actual state of production
  • available data quality, and
  • the extensive potential of a FELIOS implementation.

 

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