Automatic precast production planning algorithm

Engineering | Production | Logistics | Assembly

The two precast production plants are one of the busiest entities in major industrial group’s engineering-production-delivery-assembly value chain. The production is carried out in 3 shifts 7 days a week for most of the year. At any given moment there are around 5,000 elements in the system available for production.

Before implementing the custom the production planning solution, we faced two major challenges: 1) Prioritizing production orders from 20 simultaneous construction projects; 2) optimizing element layout on the 24 pallet carrousel production line.

By executing these tasks manually, production and project management often ran into problems that stem from sub-optimal production schedule and on average were able to achieve only 60-65% pallet effective area utilization.

We tackled both of these challenges when developing the solution. Now that we have had the algorithm in place for almost a year now, we have seen almost 20% production capacity increase, there is almost no manual interaction required for making adjustments in production schedule and project orders are executed according to their objective multi-criteria priorities.

Functionality:

  • Aggregates all manufacturing projects and evaluates all uploaded elements within the system at current state;
  • Integrates with Tekla Structures of other engineering software;
  • Gathers data on element level (type, dimensions, weight, part-list, etc.);
  • Automatically creates optimal production schedule based on:
    • Element assembly date;
    • Project priorities;
    • Availability of workshop drawing;
    • Availability of element parts;
    • Availability of production resources:
      • Number of pallets;
      • Pallet sizes;
      • Number of shifts;
      • Worker capacities within shifts;
  • Optimizes element layout on pallets based on pallet size and element dimensions and returns visual preview of the suggested layout.

Benefits:

  • 20% production output increase as compared to manual planning;
  • Almost zero manual adjustments to plan required;
  • Objective multi-criteria production order prioritization;
  • Significant decrease in planning errors due to engineering, assembly planning, logistics and production software integration.

Leave a Reply

Your email address will not be published. Required fields are marked *