Industries Ling upgrades its software and uses Syncrun to enhance the company's operational capabilities.
Many management and management personnel mistakenly believe that the process of setting production schedules by time cannot be automated because the production process often changes and is subject to many relevant conditions. Normally, the emergency treatment in the company has become a common practice, but the original time plan is actually a virtual one.
However, this kind of operation can actually benefit from the advantages brought by the latest information technologies, especially when using production planning software. Production managers using these new tools can better control the operating environments that appear to be beyond their control.
Faced with increasing sales volume and increasingly fierce market competition, the senior management personnel of Industrial Ling Company in UK (Warwick, UK, which specializes in producing folding carton packaging for users) turned to a local Arimasoft company for help. The company specializes in developing production planning and scheduling software. Less than a year after adopting this software, it has brought huge benefits to the plant, and it turns out that managers' choices are wise.
Faced with a challenge, Industries Ling employs approximately 350 people. Last year, it produced more than 1 billion folded cardboard boxes and achieved sales of more than US$110 million, making it the largest manufacturer of its kind in North America. It serves clients such as Culinar, Quaker, Johnson & Johnson, and Molson. In the past five years, the company's sales have doubled and many new products have been developed.
However, like most of the world-class companies, the company is still trying hard to produce better products to meet the increasing requirements of customers, as well as the customer's increasingly demanding practical requirements for packaging products.
Therefore, forecasting the short-term labor demand and arranging the production schedule for each machine in more than 40 production facilities becomes the main task of the company's production planning department.
In order to be able to implement the business in a dynamic environment, the most important task of the department is to arrange the order within the next four weeks. This task is to co-ordinate approximately 5,000 different operation items. The company has an average of 150 new orders per week, plus about 50 daily rotations. And because there are often many changes or unpredictable events, production plans often have to be completely changed.
In the past, Industries Ling used the Enterprise Resource Planning (ERP) system combined with the company's internal spreadsheet production software and other representative production planning tools to arrange production.
However, as the ERP system could not arrange and optimize the operation process, as the production of Industries Ling's production increased more than twice as much, the tools used by the company quickly became a major obstacle to the company's growth and diversification.
At that time, the production plan specification could not be analyzed within a reasonable length of time, the equipment installation cost could not be controlled, the time schedule could not reach the desired effect, and the management personnel were in a passive state instead of being proactive. jobs.
Arimasoft's challenge is to enable Industries Ling to have greater flexibility in arranging its production schedules and to ensure that paper processors can respond as quickly as possible to customer needs, while production costs are only part of the original production system.
Syncrun software is the time for Industries Ling to use improved planning and scheduling techniques to ensure that all production departments are coordinated, plan and marketers are integrated, and, most importantly, solutions can be quickly created. Minimize production costs.
In addition, the solution also needs to be able to simultaneously process all operations for each order, to reduce the time of order in the factory, optimize the efficiency of the use of the machine, the operating time is arranged in the right range, in the actual operation according to the workshop The feedback is adjusted and the analysis of operational processes such as machine faults is performed within one minute.
These requirements are very exaggerated and contain all the requirements that you want to achieve. This is the task that Arimasoft's proprietary software, Syncrun, will implement to provide planning and scheduling solutions for the printing and print packaging sectors.
Gaining Benefits After installing Syncrun software, there are many benefits for the company in workflow processing, total finished product production, print preparation time, waste of raw materials, and customer service. The new schedule system will arrange the tasks more rationally so that these tasks can be performed simultaneously, reducing the workload of the operation process by 12%. By adopting this mode of arranging activities, Syncrun reduced the total number of finished products by 15%.
In the folding carton industry, the print preparation time often accounts for 25% to 40% of the machine's running time, and the Syncrun software's built-in optimization algorithm can analyze millions of possibilities, find the most suitable production sequence, and reduce the data.
Installing Syncrun software can reduce the preparation time of all equipment, which means that more products can be produced under the same production capacity, and the waste of raw materials is also reduced by 6% to 8%.
In addition, the timing of the system also helps to better manage all property and delivery processes. Although no precise calculations have been made, Industries Ling has made significant progress in the timely delivery of goods.
Customer service representatives can also answer customer's questions about business progress and order arrangement in the factory faster and more accurately.
Other difficult-to-measure advantages include the possibility of analyzing different production plans, better predicting production bottlenecks in factories, formulating more accurate and longer-term production plans, and enabling better synergy between customer service and production.
“Syncrun software maximizes our production capacity and optimizes our time to meet our customers' transportation needs,†said Raymond Beaulieu, CEO of Industries Ling. “This technology was unbelievable a few years ago. It The advantages are very attractive."