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

In the highly specialized chemical industry, a producer of paints for indoor and outdoor buildings operates with 460 employees across 5 locations and maintains 31 production lines of varying batch sizes. 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 paint producer’s scheduling was fraught with inefficiencies due to several issues:

  • 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.

    Solution:

    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.

    Benefits:

    The implementation of QLECTOR LEAP enabled several significant benefits:

    • 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.

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