Planning process optimization: performing better with the right tools

Case Study: improving planning and production processes with structured tools and methods to increase precision and efficiency.

Marine
Planning

Grafica astratta con tre icone circolari illuminate disposte in fila orizzontale, rappresentante i case study.

The Context

Planning based on incomplete and non-integrated data

Project focus: production planning and scheduling, with the goal of improving the efficiency and precision of medium-to-long-term scheduling. The client contacted us because they needed to structure an effective method for medium-to-long-term planning in order to achieve more accurate production scheduling.

The Project

Structuring an integrated and reliable planning process

The project introduced a planning model based on data and tools, integrating demand forecasting and production.

Client Industry

A company producing marine components, needing to improve production planning.
Initial Situation

Production planned only based on acquired customer orders, without a forecasting vision.
Critical Issues Identified

Difficulty in assessing line saturation and coordinating production and procurement.
Project Objectives

Creating a structured and integrated planning model across company functions.

Solution

Product segmentation and production plan development

We intervened by structuring a planning process based on historical data and segmentation logic. We analyzed and classified finished and semi-finished products based on frequency and characteristics, distinguishing between Make to Stock and Make to Order logic. We then conducted an analysis of sales data from the last two years to identify trends and seasonality, which are essential for building reliable forecasts. Based on this, we developed a 12-month Master Production Schedule, integrating forecasted demand and production capacity. The new model improved visibility into line saturation and optimized scheduling, also allowing for order consolidation and more effective management of production loads.

Project Phases

Data analysis, segmentation, and production plan development

The project was developed through historical data analysis, product segmentation, and the creation of a medium-term production plan.

Step 1

Analysis

Sales data

Analysis of two years of data to identify demand trends and seasonality.

Step 2

Segmentation

Product classification

Definition of Make to Stock and Make to Order logic based on product characteristics.

Step 3

Planning

12-month MPS

Development of the production plan, integrating forecasted demand and production capacity.

Results

More structured planning and greater operational control

The project improved planning quality, increasing visibility and integration between production and procurement.

Outputs Obtained

Project Deliverables

-50% time spent on resource reorganization

Time spent on resource reorganization across production lines, thanks to line saturation and production order consolidation tools.

Greater visibility

Better control of line saturation and production loads.

Structured planning

Introduction of a model based on data and demand forecasting.

Functional integration and more effective decisions

Alignment between production, demand, and procurement. Greater planning capacity thanks to structured tools and data.

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