Chemicals Batch Production Scheduling

Production Scheduling
The Client

Leading Global Chemicals Manufacturer

The Opportunity

Client wanted to find a more automated and better way to create and maintain the production schedule across several batch reactors and schedulers.

The Approach

Profit Point engaged with the customer to design a production scheduling tool using Aspen Tech’s Aspen Plant SchedulerTM.

The tool was required to have the following features:

  • Interface to Enterprise Resource Planning (ERP) system to automatically download data from and upload data to the ERP system
  • Share schedules of production activities between multiple schedulers
  • Show total consumption of shared raw materials and with accurate timing
  • Schedule all equipment that can constrain production including unloading racks, reactors, blenders, auxiliary tanks, storage tanks, packaging lines and loading racks
  • Schedule production activities, non-production activities (i.e. cleanings) and downtime
  • Schedule planned production via a product wheel
  • Schedule both Make-To-Order (MTO) and Make-To-Stock (MTS) products with different logic for each including automating repetitive / menial tasks and schedule with heuristics / optimization where appropriate

 

The Results

The client has been able to:

  • Reduce the amount of time required to generate a schedule on a daily basis and allow for evaluating “what if” scenarios such as for unanticipated downtime
  • Increase equipment utilization delaying capital expenditures
  • Reduce both raw materials and finished goods inventory while increasing customer service levels
  • Annual savings are on the order of hundreds of thousands of dollars each year

 

 

About Mark Rockey

Mark Rockey is a Production Scheduling and Supply Chain Planning Practice Leader at Profit Point. He has spent 20+ years applying analytic techniques to solve real world problems in network design; production and distribution planning and scheduling; and capacity analysis and design.

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