AI SHOP FLOOR Scheduling Enhances Production Efficiency at Mariasteen
Mariasteen, a manufacturing company with 100 work centers across metalworking and assembly, faced significant operational challenges.
Managing 30,000 customer orders annually with 3,000 unique articles led to scattered data across systems.
Supervisors spent excessive time replanning, operators lacked clear instructions, and late orders required constant expediting.
Additionally, there was limited visibility of work-in-progress, and new staff struggled with onboarding due to product complexity.
Delivered Solution
- Flexible Scheduling Solution: AI-driven scheduling optimized resource allocation, balancing hard, medium, and soft constraints to adapt quickly to changing priorities, urgent orders, and staff availability.
- Order Release Management: Digitized order release process ensured efficient task prioritization and dynamic scheduling, reducing manual replanning.
- Digital Work Instructions: Operators received clear, real-time instructions, improving task clarity and minimizing downtime.
- Real-Time Production Monitoring: Management gained live visibility into production progress, improving decision-making and reducing delays.
- Data Integration: 24Flow consolidated scattered data, providing structured insights for better resource planning.
Digital journey through collaboration
- €200,000 Annual Savings: By streamlining planning processes, improving resource allocation, and reducing delays, Mariasteen forecasts significant cost savings.
- Enhanced Visibility: Real-time insights allowed management to track production status, identify bottlenecks early, and proactively adjust schedules, improving planning accuracy and reducing delays.
- Time Optimization: Supervisors can reduce their daily planning time from 3 hours to just 30 minutes, enabling them to shift focus to higher-value tasks like problem-solving and process improvement.
- Improved Staff Efficiency: Digital work instructions provided clear guidance for operators, minimizing downtime, reducing errors, and helping new employees become productive faster.
- Better Customer Satisfaction: Faster throughput times, improved order prioritisation, and enhanced delivery reliability resulted in happier customers, fewer urgent escalations, and increased trust in Mariasteen’s ability to deliver on time.
Key characteristics
Deployment at Mariasteen
Mariasteen’s transformation was more than just digitizing processes; it revolutionized their scheduling approach. With 24Flow, Mariasteen introduced flexible scheduling that adapts to shifting priorities, urgent orders, and staff availability. This improved scheduling reduced delays, streamlined planning, and empowered teams to focus on value-adding tasks, enhancing efficiency and performance.
High-mix, low-volume
With 100 workcenters across metalworking and assembly, 14,000 customer orders annually, and 3,000 different articles, Mariasteen operates in a demanding high-mix, low-volume environment
Any device technology
With 24Flow, Mariasteen’s teams access real-time insights, instructions, and schedules from any device, ensuring seamless communication and efficient decision-making.
Seamless integration
24Flow integrates effortlessly with SAP ERP for streamlined production data and Syntegro HR for workforce management, ensuring smooth information flow across systems and improved operational efficiency.
Low-code architecture
24Flow’s modular design and low-code architecture enable rapid deployment and easy customization. Mariasteen can independently maintain and extend the platform, ensuring it evolves with their operational needs.
Robust scheduling is not just a dream
Mariasteen, a manufacturer with 100 workcenters across metalworking and assembly, faced significant scheduling challenges. Managing 30,000 annual orders with 3,000 unique articles created a complex planning environment. Planners previously relied on paper timetables and complex Excel sheets, which were prone to human error and struggled to accommodate real-time changes. This inefficiency led to delays, stress for staff, and difficulty meeting customer deadlines.
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ABOUT US
24Flow is a modular shop floor management and production scheduling platform that empowers discrete manufacturers to reduce lead times through digital support of operators and management. Inspired by lean and QRM, 24Flow controls the flow of production orders which increases visibility and results in shorter lead times, improved delivery reliability and a reduction of work-in-progress and inventory.