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Caleffi

How Caleffi managed the steady production growth

The Company

Caleffi is the leader in the engineering and manufacturing of high-quality components for heating, plumbing, air conditioning, heat metering and renewables systems, for domestic and industrial plants. In 2016 more than 1,000 employees all over the world, 12 companies, 5 offices, 3 manufacturing premises all set in Italy and more than 70 active markets; the consolidated turnover recorded more than 300 million euros.

 

The Challenge

Continuous search for new markets has involved a strong expansion of the product portfolio, over the years, resulting in an increase of the production mix that has led the company to the current 7,000 product items.

Interview to the Group Operations Manager – Giorgio Milan and the Group Planning Manager – Filippo Portigliotti.

“The strong increase of the complexity resulted in a ineffective production line-up for product as for the production organization of up to a few years ago. The consequent shift to a job-shop model (where currently are operating about 200 work centers on 2 factories for mechanical machining departments, plastic molding and assembling) has clearly revealed the need for greater control of workloads resulting from the production plan. It also showed the need for better synchronization in the materials planning in order to contain inventory levels of semi-finished products and total crossing time while maintaining the already excellent service level.

Conscious of this needs, we concentrated our efforts towards the definition of a planning process that takes into account the availability of materials and production resources in the creation of the production plan in order to have reliable dates about stock availability. In Caleffi we used a production scheduling solution that had the huge limit of not managing the need of the different materials. Therefore we decided to organize a software selection that would allow us understanding the state-of-the-art of the production planning solutions.”

 

The solution

“During this selection process, that lasted nine months, we have been able to evaluate six different products. In the end, Cybertec’s CyberPlan has been choosen because it demonstraded the only one to cover all the planning processes, from the mid term to the detail scheduling, all integrated in a single product. It also has a standard integration module with SAP that allowed us to enormously reduce the risk of interoperability, a critical factor in these projects, as well as greatly reducing the commitment in terms of internal IT resources. Finally Cybertec distinguished itself for the consulting approach that has been visible since the early stages of sales, proposing itself as a strategic partner, which allowed us to make a technological choice that took into account a medium-term evolution of our planning process.

CyberPlan’s introduction project has been organized in several phases. The first one allowed us to solve a critical issue already after a few weeks: the extraction of data contained in SAP. This stage, which experience has taught us to be critical and that makes the difference, was profitable, reliable and highly performing. During the project there was the need to manage some “custom” data (which are specific to our company) this has been handled with great competence and quickness from the Cybertec team. The project covered the finite capacity planning and scheduling processes, up to the publication of the work-plan directly on each single location, with about 150 active locations and nearly real-time synchronization with data collected from the field. The outstanding expertise, availability and professionalism of the Cybertec team in supporting the project enabled us in adopting the best solution for each specific need of ours.”

 

Results

“We appreciated an improvement in the ability to manage and control production resources, an improvement in inventory levels together with an increase in the already good service level to the market. The control activities for missing materials has been drastically simplified and is now highly effective and immediate.”

 

Endorsement

CyberPlan has been unique in covering all the planning processes, from the mid term to the detail scheduling, all integrated in a single product.

Eng. Giorgio Milan
Eng. Giorgio Milan
Group Operations Manager

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