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DESCRIPTION
Products such as cars are available in an increasing range of colors. The paint shop schedule, hence, has to handle more colors, yet minimize the number of color changeovers. The Optessa schedule not only handles all paint shop rules but also applies all the requirements from other plant areas (and suppliers if relevant).
Improving Order Sequences by Replacing a Legacy System A major auto OEM was faced with the challenge of replacing its legacy system for order sequencing. With increased complexity due to new models and production mixes, the current solution was not able to perform and solve the OEM's production challenges.
Use Case | Increase Throughput and Unlock Capacity with Optessa Optessa high throughput schedules. For example, an annualized benefit of $2 million was evaluated by an engine manufacturer based on an over 9% throughput improvement provided by the Optessa schedule as compared to the previous scheduling process.
A global manufacturer, with a strong brand and reputation for producing quality high-value products, started losing market share. The operations teams quickly discovered that customers were leaving because they could no longer depend on the timely delivery of the manufactured goods.
Use Case | Reduce Cost by $ Millions when Considering All Factors Significant cost savings accrued from just the sunroof spacing constraint. When all rules and constraints were considered, the annual cost savings for a single car plant was estimated at $4 million.
The auto industry deals with production of orders from different sources. Some units are made-to-order and come directly from the final customer, while other units are made-to-stock and come from sales forecasts. Made-to-order units are often the most profitable as they already have a buyer and often utilize high-value commodities.
The previous scheduling process relied on a very large and elaborate spreadsheet. It took a scheduler a day just to create a week's schedule. For the same problem, Optessa was able to create a 2+ weeks schedule that resulted in good part batches (run of the same part) and fewer die change overs.
By better balancing the trade-offs involved through patented AI and optimization-based scheduling, Optessa can significantly reduce cleaning time and improve delivery times. Adherence to all the requirements can be verified using the many visualizations available in the system, such as the Grid Browser.
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