IBM Case Studies Analytics used to precisely plan and schedule production

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	Analytics used to precisely plan and schedule production IBM

Analytics used to precisely plan and schedule production

IBM

Technology Category	Analytics & Modeling - Predictive Analytics Analytics & Modeling - Process Analytics
Applicable Industries	Metals
Applicable Functions	Discrete Manufacturing
Use Cases	Advanced Production Planning and Scheduling Flexible Manufacturing
Services	System Integration
Challenge	Building steel mills and the related equipment is a highly complex process that requires orchestrating thousands of components, workers and machines. Lacking modern planning software, Italy-based Danieli & C. Officine Meccaniche S.p.A., a steel plant builder with factories in five countries in Europe and Asia, struggled to coordinate materials and resources, compromising efficiency and jeopardizing timelines. Read More
About Customer	Danieli & C. Officine Meccaniche S.p.A. is a large company based in Europe that designs, constructs, and sells plants and equipment for the metallurgical industry, such as steel and iron. The company has factories in five countries across Europe and Asia. The company's operations involve the complex process of building steel mills and the related equipment, which requires the orchestration of thousands of components, workers, and machines. Read More
Solution	Danieli chose a mathematical optimization solution that takes into account all production constraints of every single plant, enabling the builder to develop optimal production schedules that align with order requirements, delivery dates and manufacturing goals. If changes in production plans occur, what-if scenarios show their effect on workloads while the solution runs multiple simulations and results are delivered in a few seconds, helping Danieli schedule its flexible manufacturing system (FMS) machine operations. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Analytics & Modeling - Process Analytics

Applicable Industries

Metals

Applicable Functions

Discrete Manufacturing

Use Cases

Advanced Production Planning and Scheduling

Flexible Manufacturing

Services

System Integration

Challenge

Building steel mills and the related equipment is a highly complex process that requires orchestrating thousands of components, workers and machines. Lacking modern planning software, Italy-based Danieli & C. Officine Meccaniche S.p.A., a steel plant builder with factories in five countries in Europe and Asia, struggled to coordinate materials and resources, compromising efficiency and jeopardizing timelines.

About Customer

Danieli & C. Officine Meccaniche S.p.A. is a large company based in Europe that designs, constructs, and sells plants and equipment for the metallurgical industry, such as steel and iron. The company has factories in five countries across Europe and Asia. The company's operations involve the complex process of building steel mills and the related equipment, which requires the orchestration of thousands of components, workers, and machines.

Solution

Danieli chose a mathematical optimization solution that takes into account all production constraints of every single plant, enabling the builder to develop optimal production schedules that align with order requirements, delivery dates and manufacturing goals. If changes in production plans occur, what-if scenarios show their effect on workloads while the solution runs multiple simulations and results are delivered in a few seconds, helping Danieli schedule its flexible manufacturing system (FMS) machine operations.

Impact #1	With a centralized installation, Danieli can now calculate production costs much quicker, saving one hour for the first scheduling in the kick-off phase.
Impact #2	An additional benefit was the reduction of nonoperative time, or downtime, on machinery, which helps improve the ROI on expensive equipment.
Impact #3	Unlike before, the company’s flexible manufacturing system (FMS) machines are now working 24 hours per day, resulting in huge savings in terms of increased efficiency and equipment ROI.

Impact #1

With a centralized installation, Danieli can now calculate production costs much quicker, saving one hour for the first scheduling in the kick-off phase.

Impact #2

An additional benefit was the reduction of nonoperative time, or downtime, on machinery, which helps improve the ROI on expensive equipment.

Impact #3

Unlike before, the company’s flexible manufacturing system (FMS) machines are now working 24 hours per day, resulting in huge savings in terms of increased efficiency and equipment ROI.

Benefit #1	Saved one hour for the first scheduling in the kick-off phase
Benefit #2	Reduced nonoperative time on machinery
Benefit #3	FMS machines are now working 24 hours per day

Benefit #1

Saved one hour for the first scheduling in the kick-off phase

Benefit #2

Reduced nonoperative time on machinery

Benefit #3

FMS machines are now working 24 hours per day

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Overview

Analytics used to precisely plan and schedule production

Operational Impact

Quantitative Benefit