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Modulblok transforms and streamlines the order-based production planning process

Lean planning in contract manufacturing

The Company

Modulblok represents the reference for the production of warehouse storage and logistics systems, the company’s mission is in fact to obtain organized, performing and safe warehouses. To do this, the company respects virtuous principles such as continuous improvement and the search for personalized, original and innovative solutions. The company’s priority is to create a new culture, aimed at avoiding waste, pollution and low-value activities, based on the optimization of space, time and costs. Modulblok also works according to the principles of Lean Thinking to reduce waste to a minimum and improve safety in the workplace, engaging a virtuous circle of ever-increasing competitiveness.

 

The Challenge

The need for improvement and transformation arose from many factors that have prompted the company to adopt new processes and solutions. The research and implementation of an APS solution for advanced production planning and scheduling was one of these. The company was equipped with a management system that was not able to support the effective management of a mix between a contracted environment and a demanded environment and the generation of information regarding loads and production orders. The process was therefore manual and the production was managed on sight, the time required to calculate delivery times were too long and no longer sustainable for the level of service desired by the company; the same time of crossing was then drastically reduced to increase the company’s competitiveness.

The main objectives expected from the implementation of new processes and tools were therefore:

  • Increase the reliability of delivery dates and the speed of their processing;
  • Reduce the time required to process production plans;
  • To obtain the maximum possible visibility on the production process;
  • Facilitate communication between operations and management.

 

The solution

The project started with respect to the best practices of the sector, and therefore from the improvement of the starting data, thanks to the introduction of a data collection system to optimize the cycle changes and the data of the bills of materials. From there the need arose of an instrument that was able to give visibility on the loads and certain confirmations and quickly to the commercial department about the possible delivery dates.

The first choice made, in terms of APS solution, proved unsatisfactory because the chosen tool took too much time to develop a scheduling plan and therefore was not in line with the company objectives.

The determination to find the best solution then led the company to carry out a software selection process that proved interesting and engaging and led to the choice of the CyberPlan solution, thanks to its characteristics and quality. The Cybertec APS was implemented in just a few months.

Over time the company has grown and with it some tools and processes have also changed. The use of the CyberPlan software continued uninterrupted even when the ERP software was changed. Tells the ing. Peressi: “Keeping CyberPlan active at a time of delicate transition like that of the management system has made it possible to avoid the risk of stopping production and guaranteed the same high level of customer service.

Another feature of Modulblok is to operate according to the principles of Lean Thinking, which makes it an exceptional case, since the company operates as a contract. The transition to operating according to this philosophy has seen the use of the CyberPlan tool as support for the management of Kanban. In fact, on CyberPlan the Kanban cards have been digitized and the necessary quantities are calculated from the simulations.

A further progress in the use of the tool has been the opening of the same to different roles from the planning and scheduling of production. The sharing of the plans both with the management and with the purchasing and sales departments has made it possible to considerably increase intra-company communication and knowledge sharing, while at the same time reducing the time needed to respond to customers.

 

Results

This virtuous process of transformation of production planning together with the installation of CyberPlan, allowed the achievement of ambitious objectives and able to make the difference compared to the competition:

  • 98% service level reached;
  • 60% lead time reduction;
  • Planning cost reduction of 50%;
  • Strong reduction of the missing.

Moreover, Andrea Peressi notes “we not only halved the cost of planning, but we have standardized the whole process. The standardization of the process together with the intuitiveness of CyberPlan, allows the new planners to be fully operational in one or two weeks, completely reducing the costs of delivery steps “.

 

Endorsement

Not only did we lower the cost of planning, but we standardized and streamlined the whole process to a 98% on time delivery level.

Andrea Peressi
Andrea Peressi
Production Planning Manager

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