About the Company |
A leading producer of auto and industrial batteries with a turnover of about USD 300 million. It is one of the largest and most modern automotive battery plants in Asia with installed capacity of 2.5 million batteries per annum. |
Business Situation |
The marketing team generates the demands for the following month with daily demands, and the capacity is planned accordingly. There was no communication between planning and material procurement and handling team. This was resulting in problems in execution of the production due to lack of materials. Also, the marketing team was not informed about the expected completion date. Since they made all the products required for a battery, it was a complex supply chain, planning took about 10 days and was done once a month. This did not incorporate any unexpected delays such as machine breakdown, material rejection etc. Lack of visibility among different department’s production progress resulting in problems in downstream production and unable to find the critical resources. |
Business Solution |
Lighthouse Production Planning and Scheduling incorporated real time material and capacity constraints.Lighthouse provides future visibility to decide which procurement orders have to be expedited/ de-expedited based on capacity plan.Lighthouse provides visibility of delays such as machine breakdown, material rejection etc. . in day to day plans and make the necessary changes in the plan accordingly.Planning frequency was increased to daily run. |
Business Benefits |
Integration with their existing RAMCO ERP system Increase in customer service levelsReduced throughput timeReduced planning cycle time from 10 days to a few hoursIntegration of multiple departments for knowledge sharing Increased efficiency and responsiveness of the supply chainIdentification of critical resources and effective utilization of the same |
Key Performance Indicators |
Lead time Reduction Timely availability of materials Dynamic Planning capability Lead time Reduction |
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