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Implementing Fast ‘What-If’ Predictive Simulations at Paint Producers’ Plants

1

Locations

51

Production Lines

460

Employees

€ 80 M

Revenue

This case study outlines how this paint producer overcame significant scheduling challenges by implementing QLECTOR LEAP, resulting in a marked increase in efficiency and reduction in downtimes.
Challenges
The producer turned to QLECTOR for a comprehensive solution that included:
Ineffective Rinsing and Cleaning Schedules

Existing schedules were not optimized, leading to frequent collapses.

Manual Scheduling Processes

Coordinating schedules between planners and shift leaders manually was time-consuming and error-prone.

Complex Product Levels

Managing up to three levels of semi-finished goods and buffer tanks made scheduling highly intricate.

Knowledge Bottlenecks

A concentration of process knowledge within a few planners posed a high risk to operational continuity.

Seasonal Fluctuations

Managing human resources and stock levels during seasonal peaks added to the complexity.

The producer turned to QLECTOR for a comprehensive solution that included:
Predictive Simulations

Implementing fast ‘what-if’ simulations to quickly adapt to unpredicted events.

Automated Rescheduling

Enabling automatic rescheduling of processes and planned orders to minimize disruption.

Sequencing Optimization

Reducing cleaning and rinsing times through better sequencing of production tasks.

Long-Term Planning

Developing long-term scenarios for human resources, stock, and capacities to prepare for future demands.

The producer turned to QLECTOR for a comprehensive solution that included:
Significant Time Savings

A reduction of planning time by 50%.

Reduced Downtimes

A 20% decrease in organizational downtimes.

Extended Scheduling Horizon

Moving from daily to weekly scheduling, providing a broader operational perspective.

Conclusion

The producer’s strategic use of QLECTOR LEAP demonstrates a significant leap forward in managing the complexities of chemical production. With substantial time savings for planners and reduced downtimes, the company has set a new standard for efficiency in the chemical industry.

Keep following our use cases and blog posts to explore more about how innovative scheduling solutions are making waves in various sectors and driving companies toward a more efficient future.

Matjaž Roblek, Supply Chain Director at DOMEL, attested to the advantages brought by QLECTOR LEAP, which automated the planners’ work and managed a larger number of machines more effectively, leading to a 10% improvement in inventory lead times.

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With QLECTOR LEAP, we have digitally mapped every process within our company, revolutionizing our operations. This allows us to swiftly and efficiently formulate our production plan, complete with auxiliary workstations. The true game-changer lies in the plan's automatic updates. Simultaneously, all subsidiary processes remain informed of any modifications

By bidding farewell to a multitude of Excel files once essential for production planning, we not only declutter but also reclaim valuable time. The era of manual updates is now behind us.
I wholeheartedly recommend Qlector Leap to those who have yet to establish a systematic production planning system and still rely on Microsoft programs. The tediousness of handling such files and their susceptibility to errors can now become a thing of the past

Domen Škrbina

Head of Production Logistics at Kovis

Kovis is an internationally innovative company for the development and production of high-quality components for the railway industry and various parts for other industrial sectors. The company has established itself internationally with the production of brake discs for all types of railway vehicles: from locomotives, trams, and metro lines to high-speed trains. In addition to the brake discs, Kovis is also the largest manufacturer of axle boxes for freight wagons in Europe.
Kovis turns good ideas into a safe and sustainable future.

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QLECTOR LEAP has enabled significant progress in production plan optimization, as it learns from historical data, optimizes the plan, and provides more optimal suggestions for planners and production.

The most useful functionalities include real-time inventory overview, scheduling of workers and tool changes, and a user-friendly experience for planners, who receive a Gantt chart and a real-time overview of weekly realization. Any changes made to the plan in SAP by the planner are immediately visible in LEAP, allowing us to see when we will have reconfigurations and reduces tool change time.
The condition for using QLECTOR LEAP is well-organized data. With this condition met, LEAP operates with great precision, which is why I would recommend it to other manufacturing companies.

Marija Golja

Production Planner at Kolektor

Kolektor is a global supplier that boasts a tradition of highly specialized industrial production. In almost 60 years of experience, the company became a global provider of mobility components and systems and has added programs outside the automotive industry in the process of diversification and globalization and has spread to other continents.
Kolektor is a synonym for credibility, trust, quality, and innovative products and services. The programs are managed in three strategic groups: Kolektor Mobility, Kolektor Technologies, and Kolektor Construction.

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Qlector's software optimizes production planning in a simple, intuitive way and opens up new optimization options in a simple form thanks to the AI algorithms and various evaluations and reports. A must for modern production

Ingo Hild

Plant Manager at ams OSRAM Group

ams OSRAM is a global leader in innovative light and sensor solutions, building on over a century of experience. Combining engineering expertise with global manufacturing, the company delivers groundbreaking applications that make the world safer, smarter, and more sustainable. Specializing in high-quality semiconductor-based light emitters, sensors, and software, ams OSRAM continues to push the boundaries in illumination, visualization, and sensing across diverse industries.

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QLECTOR LEAP has enabled the automation of planners' work, faster response to changes in production planning, and management of a larger number of machines.

The results are currently evident in shorter inventory lead times for binding unfinished production and semi-finished goods, where we observe a 10% improvement. I would also highlight the expertise and agility of the Qlector team in terms of understanding and adapting to our production planning peculiarities. Domel follows modern trends in digitization, which is why QLECTOR LEAP seamlessly integrates into the ERP and MES system and is certainly one of the AI integrated APS solutions worth exploring.

Matjaž Roblek

Supply Chain Director at Domel

Domel is a global development supplier of electric motors, vacuum motors, blowers, and components. The company was founded in 1964 and has production facilities in Slovenia, Serbia and China. Their motors power over 300 million appliances in premium and consumer markets worldwide. Domel’s business processes employ high levels of technology, automation and robotisation, which form a basis for building competitiveness and excellence.