A topic with potential for conflict
Creating a good detailed plan for production is a complex topic with potential for conflict. On the one hand, the delivery dates and material availability of the production orders must be taken into account during planning. This aspect is usually well supported by the ERP system, which breaks down parts lists, generates orders and carries out rough planning in the course of the MRP run in order to meet delivery dates as far as possible. On the other hand, production capacity must also be taken into account in the production planning process. This raises the question: On which machine does the order run and when? Which personnel with which skills are required? When is the necessary special tool available and when will it be used for other production orders? These considerations result in complex restrictions and conditions that must be taken into account in order to create an executable production plan. Without the support of software, it is almost impossible to maintain an overview.
Optimizing the plan: A major challenge
The next challenge is to optimize this plan. A production plan should not only be executable, but also optimize KPIs such as capacity utilization, setup times and adherence to delivery dates. To do this, it is necessary to find a good allocation of production orders to machines, personnel and special tools. In addition, optimal sequences must be determined in order to make the best possible use of critical bottlenecks. The use of software for optimized detailed planning is absolutely essential for this task at the latest. Creating a good plan just once is therefore a demanding task. But this is not where the challenges end: a good plan created once is of little help in optimizing production. Rather, it is necessary to have a good plan at all times. This means that you have to react quickly and in a targeted manner to changes at all times.
Every machine breakdown and every employee on sick leave requires an adjustment to the production plan. The same applies if material is not available at short notice or a production order takes significantly longer than originally expected. Planning on one day a week and then working according to this plan for the whole week will hardly work. This leads to improvisation and chaos on the store floor. And every time the plan is adjusted, all the considerations that are necessary to create a single plan must be taken into account! This clearly shows that planning well once is difficult, but always having a good plan is even more so! Software for detailed planning must be designed from the ground up to enable quick, efficient and targeted reactions through adjustments to the plan. This is the only way that detailed planning in production can be successful in the long term.
What really helps?
This is where the added value of using artificial intelligence (AI) in detailed planning becomes apparent: when decisions need to be made quickly, AI can support people by specifically identifying and investigating relevant adjustment options in the plan. This means that adjustments can still be made in a well-founded and targeted manner despite the need for a quick decision. AI makes it possible to react to changes in real time and select the best possible alternatives, which significantly increases the efficiency and stability of production processes.
