Never again
"We've always worked like this."

Just imagine: Your production is running! There are hardly any planned downtimes and you are relaxed about the complex interrelationships that have to be taken into account in production planning. This is the new world of production with PAILOT.

Standstill was yesterday.

Thanks to our AI-based algorithms, the handling of extensive data in production planning and detailed planning is not only more intelligent, but also more efficient. Complex interrelationships in detailed production planning are controlled in a targeted and precise manner.

Say goodbye to old patterns and complications in the production planning and detailed planning of your production. With PAILOT, your production runs with reduced downtimes, and the solution to unforeseen events is at your fingertips.

Cloud-based and ready for immediate use.

PAILOT is flexibly integrated into your IT and IoT systems and is immediately ready for use as a cloud service. Order-related data from any system can be easily exchanged via modern interfaces. Near-real-time data can be integrated effortlessly and, if required, PAILOT can be provided via Excel integration.

Our experts accompany you during implementation with tailored adaptations, training and support. Seamless integration into existing systems ensures a smooth transition and consistent data management.

Better safe than sorry.

Hacker attacks are no longer a rarity. According to a survey by Statista, around 58% of German companies surveyed stated that they had been the victim of a cyber attack at least once in 2023. If a cyber attack hits the IT system of a manufacturing company, this can lead to considerable financial damage.

We know how important it is to protect against external attacks and therefore work with AWS (Amazon Web Services) servers that are hosted in Germany. This approach guarantees the best possible protection for our customers and their production. 

Modules that adapt to your production

PAILOT combines three modules in one. The core is our bundle of the latest generation of algorithms. We have developed our PAILOT Bridge for easy data transfer. The PAILOT Cockpit ensures transparency and clarity of the current production runs.

PAILOT Engine

Our centerpiece: AI-based algorithms of the latest generation achieve optimal plans in a matter of seconds.

As we work cloud-based, our engine is available at all times.
PAILOT Engine is implemented as a microservice in just a few steps.
High levels of complexity and lots of data are no challenge for our algorithms.

PAILOT Bridge

Our adapter: Data of any form and origin form the basis for the calculation and can be easily integrated into our engine.

PAILOT Bridge can be used to process data from any MES or ERP system, e.g. SAP.
Data from any MES or ERP system, e.g. SAP, can be processed and data from Excel can also be easily transferred to our engine.
You will receive the plans we provide in the format of your choice.

PAILOT Cockpit

Our web interface: The generated production plans are displayed on our user-friendly and clear interface.

Order data is presented clearly and intuitively in the form of production and capacity plans as well as worklists.
Short-term disruptions can be easily responded to by entering absences and downtimes.
Spontaneous changes to the situation can be made directly by adjusting the start or end date.

Your added value with PAILOT

Production

Even in challenging times, PAILOT makes it possible to work more calmly on the store floor thanks to less planning effort.

Production management

Production management with PAILOT is characterized by its ability to react quickly to disruptions and automatically takes into account all the limited resources available.

Distribution

Sales are optimized through improved on-time delivery, shorter production times and transparent information on current production orders.

The company

With PAILOT, the company benefits from lower capital costs, increased output, higher machine utilization and reduced set-up costs.

PAILOT in action: Best Cases

Constab site

Plastics manufacturer CONSTAB - with 17% more output

The initial situation

Several planners, production orders in the three-digit range per month, executed on different systems. There is a wide variety of product types that can be produced at different speeds on different systems. The set-up and cleaning times also depend on this combination. Last but not least, material availability and boss orders made for a Herculean planning task.

The solution

PAILOT automated the distribution of orders to "suitable" production systems. As a result, set-up and cleaning times are minimal - with maximum throughput and guaranteed delivery dates. Overall, the output increased by 17 percent, the planning effort was reduced and production became more responsive.

A production hall in mechanical engineering

Mechanical engineering - with 28% fewer delays

The initial situation

This example focuses on two individual turning-boring-milling centers of a special machine manufacturer. Over the course of a month, six different products with different delivery dates and set-up times as well as different production times (from 2 to 5 hours) have to be machined on these centers. This results in 720 possible processing combinations.

The solution

PAILOT analyzed the historical production data. What would have happened if the orders had been processed in strict chronological order or, alternatively, if only setup-optimized processes had been used? Both approaches lead to many delays with different set-up times. In contrast, PAILOT carried out a combined calculation of the production sequence. This reduced the number of delays by 28% and set-up times by 21% compared to the previous process.

Sick building

Sensor manufacturer - with 10 % more capacity utilization

The initial situation

The sensor manufacturer has a plant with 30 machines / workstations that are highly automated. All components go through a multi-stage production process on various machines, whereby they are transported using AGVs (automated guided vehicles) - which must be taken into account during detailed planning. Optimization software was already in use at this plant.

The solution

PAILOT intervened in the sequence of the production processes here, increasing the plant's capacity utilization by 10 percent. This was made possible by a different arrangement of the individual production tasks on the machines - for example, because the component with the shorter processing time is brought forward on machine 1, machine 2 does not have to wait unnecessarily for the start of the second processing step on the same component (or vice versa). The various waiting times are thus massively reduced.

Download our practical guide now and learn more about the potential of detailed planning

Practical guide to introducing a new generation APS solution

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A comparison of the most important functions

Get started with our unique demo version to experience the potential of your production with PAILOT using your own data. With the full version, you can exploit the full potential.

Function

Demo version

Full version

Selection and weighting of the optimization criteria

done

done

Optimization criteria can be individually combined with each other. For example, on-time delivery, capacity utilization, production volume, set-up times.

Individual selection and weighting

Once per test environment

Alternative work plans

done

done

Production steps can be manufactured on different machines. The machines can be of the same design or have different production speeds

Limited to identical machines

External production steps

close

done

Placing orders with external service providers. These can be alternative work plans or production steps that are always produced externally.
Express orders

done

done

Orders that must be produced next due to high priority.
Set-up / cleaning

done

done

Processes during which the machine is at a standstill to change the configuration. The duration of the processes can depend on the sequence.

Limited to set-up matrices

Limited operating resources

close

done

Certain operating resources such as tools or cleaning aids are only available in limited quantities. Availability is ensured during planning.
Illustration of the current machine assignment

close

done

There are production steps that already run on the machines. This is taken into account in the (re)planning.
Order editing

done

done

Adjustment of the following data directly in the graphical user interface: Earliest start, latest end, express order status.
Calculation and output of KPIs

done

done

Relevant KPIs are calculated for each generated plan and output in the desired format.

Standard KPIs

Individually defined KPIs

Display of meta information

close

done

Display of additional order information (e.g. product descriptions, order numbers, setup information, free texts).

Function

Demo

Full version

Selection and weighting of the optimization criteria

done

done

Alternative work plans

done

done

Production steps can be manufactured on different machines. The machines can be of the same design or have different production speeds

Limited to identical machines

External production steps

close

done

Placing orders with external service providers. These can be alternative work plans or production steps that are always produced externally.
Express orders

done

done

Orders that must be produced next due to high priority.
Set-up / cleaning

done

done

Processes during which the machine is at a standstill to change the configuration. The duration of the processes can depend on the sequence.

Limited to set-up matrices

Limited operating resources

close

done

Certain operating resources such as tools or cleaning aids are only available in limited quantities. Availability is ensured during planning.
Illustration of the current machine assignment

close

done

There are production steps that already run on the machines. This is taken into account in the (re)planning.
Order editing

done

done

Adjustment of the following data directly in the graphical user interface: Earliest start, latest end, express order status.
Calculation and output of KPIs

done

done

Relevant KPIs are calculated for each generated plan and output in the desired format.

Standard KPIs

Individually defined KPIs

Display of meta information

close

done

Display of additional order information (e.g. product descriptions, order numbers, setup information, free texts).

Revolutionize your detailed planning now with PAILOT

You will receive more detailed information about optimization options for your production in an initial non-binding consultation.

Start now

Any questions?

From what production size and structure is PAILOT worthwhile for a company?

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PAILOT is suitable for small and medium-sized companies as well as for large, complex plants. Our customers' productions range from 7 machines to 200 machines and 600 employees in production. PAILOT is particularly suitable for discrete manufacturing with a store floor or flowshop setup, especially with complex multi-stage production, personnel skills and set-up processes. Our system is less suitable for high-volume production or pure line production.

How much time passes between commissioning and the first detailed plan created with PAILOT?

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A detailed plan can be created within a few days, provided the data is transferred in the previously defined format. The go-live project is completed within 3 months so that PAILOT is fully integrated into the systems and processes and offers full added value.

For which industries does PAILOT offer added value in production?

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PAILOT offers added value for all manufacturing companies with discrete production, but especially for companies in the electronics and metal processing sectors.

What cost models does PAILOT offer?

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PAILOT works as a Software as a Service product with an annual rental fee. The costs are based on the number of machines to be planned. All updates are included in the fee and are provided continuously so that there are no interruptions in use or time-consuming update processes for you. We also offer a performance-based pricing model on request.

Does a company have to use all modules of the PAILOT Suite?

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No, that's not necessary. Our engine, the heart of the system, can be flexibly combined with cockpit and / or adapter.

Does PAILOT also offer on-site service and advice?

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As a rule, an implementation project begins with an on-site appointment. After that, most of the collaboration takes place remotely, although we are also available to visit you on site at certain points.

Is it possible to test PAILOT before a final, binding implementation?

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Yes, we provide a 30-day trial version. If you are not satisfied with PAILOT, you can cancel on a monthly basis within the first year.

What technical conditions must a company have in order to be able to implement PAILOT without any problems?

Down arrow

Your company should have ERP and BDE (production data acquisition). An MES system is often helpful. PAILOT also uses data on delivery dates, work schedules and the availability of machines and personnel. If setup optimization is required, setup times should also be available. PAILOT runs in the cloud and is compatible with any IT setup (hardware and software).

How does PAILOT ensure that the detailed planning software is always up to date?

Down arrow

As a cloud-based system, PAILOT is continuously updated. This is done while the system is running, so there are no interruptions. Every new function is automatically made available to all customers.

Down arrow

How does PAILOT ensure that the detailed planning software is always up to date?

In this case, we recommend using the bridge. You only have to worry about providing the data and with our bridge we take care of the technical integration work for you. This means you can go live with PAILOT in just a few weeks, even without IT resources.

Still have questions? We look forward to hearing from you at info@pailot.com
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