Multi-site Aluminum Finishing Planning, Scheduling & Optimization

Common planning and scheduling solution implemented across three (3) major North American Aluminum plants

  • One plant (using Oracle ERP) was experiencing operational issues as a result of combing multiple plants and production lines into one facility
  • Another plant’s complex planning and scheduling relied on one scheduler who performed manual interventions. MRP and BOM (bill of materials) structure was inflexible, leading to suboptimal [production]
  • The third plant was entering a new market (automotive body sheet) and required optimized planning to keep up with tough contract demands

Benefits:

  • Increased visibility of upcoming production issues
  • Optimal production plan and schedule
  • 32% increased throughput (360,000 lbs) on a key coating line
  • 5% reduction in wasted metal through better usage
  • Forecasting a 9% increase in production plan next year