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Clementoni: growth and greater control with CyberPlan

Manage production growth thanks to a planning and scheduling tool

The Company

Clementoni was founded in Recanati in 1963 following the brilliant intuition of its founder who decided to bring to Italy a previously unknown product, the board game. Clementoni has always set the ambitious goal of supporting children in the delicate process of psychophysical development, through the language they know best and which is their natural form of expression: the game. Today Clementoni is an industrial reality of primary importance, strongly projected towards foreign markets and, at the same time, very rooted in its territory of origin.

 

The Challenge

Initially, when the company was still predominantly artisan, the production planning was carried out by the department heads using folders, sheets and printouts and also the scheduling was carried out manually. All this was possible and adapted to the dimensions of the time, where the number of codes was very small.

The problems occurred simultaneously with the growth in the company market, which in the Supply Chain translated into greater number of codes to be managed and quantities.

At the same time problems of communication between production and commercial office arose, in fact the information was not always updated.

The company therefore needed to manage the strong growth it was experiencing, providing itself with a structure that would allow the production process to be monitored.

We needed a software able to give a global vision of the needs, of the stocks, considering the production progress: So we had a greater visibility of the availability of raw materials and semi-finished products in order to organize the entire workflow. A general “glance” and maybe not very updated, was not enough anymore.

For the programming office arose the need to increase the visibility and access to information that had to be all available in the same environment, in real time and all subject to processing even by multiple users at the same time.

The planning of production also required greater precision and punctuality. The premise to this was the ability to assess loads well and manage the saturation of the machines. It needed an easy tool, with an immediate glance that would help define the current and future production capacity for each work center / machine.

Considering also the “toy product” that is affected by a great seasonality, it was necessary to increase and simplify the dialogue and the quality of the information exchanged between the production and the commercial department.

 

The solution

Clementoni decided to acquire new tools.

A software selection was then carried out to identify the best solution that would allow Clementoni to evolve the methods and tools used to manage the entire supply chain. The company was determined to innovate, increasing the potential of the planning department, increasing its versatility, but maintaining its size in terms of dedicated people. In addition, the integration of the purchasing part, in line with the sales forecasts and the production process, has made it possible to better manage the components with a long lead time. Clementoni thus selected CyberPlan, the APS deleveloped by Cybertec, to plan and schedule the production at finite capacity.

The biggest and most recent implementation, which took about a year, took place in relation to other IT tools and found in Cybertec’s consulting all the support and knowledge necessary to get the maximum benefit from this innovation.

Thanks to its foresight and to the CyberPlan solution, Clementoni has grown considerably in recent years, rising from a turnover of € 80 million in 2001 to one of € 187 today, all this maintaining a substantially similar structure, remaining therefore agile and streamlined.

 

Results

CyberPlan proved to be a versatile and fast tool that allows Clementoni to schedule production with greater ease despite the considerable growth of the company, also in terms of complexity.

Production planning has seen an increase in the number of codes managed, the saturation of the work centers and the need for visibility on the future load. The management of all this has been possible thanks to the immediate and concrete visual impact given by CyberPlan to analyze the capabilities of the production process.

The relationship with suppliers has also benefited from the new solution. Thanks to the APS instrument, in fact, the suppliers of Clementoni know the quantities and terms of production requests with immediacy and without barriers.

CyberPlan also supports the executives in the management of the company structure thanks to visibility on future production and needs in terms of hours and equipment.

 

Endorsement

The characteristics that we like most of CyberPlan are the speed with which we access information, and its calculation capacity that allows us to manage the schedule in agile times.

Alessandro Angeloni
Alessandro Angeloni
Senior Production Planner

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