Flexible, tool-based methodology for line-side and supply planning

The end-to-end planning of the entire line-side and supply logistics, from suppliers to in-house assembly lines, is a planning challenge when there are a large number of part numbers and a wide variety of parts. The complexity is further increased by significant fluctuations in the quantities of the product types to be assembled, such as in a highly flexible engine assembly line. The logistical quantity structure (LMG) serves as the starting point for all planning. As it is subject to constant change, flexible adaptation of the provisioning system, material flow and tugger train concepts, picking in the supermarket or warehouse, and inbound supply models from suppliers is required. Our solution aims to manage this dynamic landscape efficiently: We have created a tool solution that supports planners with predefined planning modules and predefined MTM values (mean time methods or determine MTM sizes depending on the context). A wide variety of principles in material provision, parts picking or tugger train supply can thus be flexibly modelled, standardised, evaluated and integrated into the planning process.

Key aspects of the methodology

• Predefined planning modules: The solution offers a library of predefined planning modules (e.g. procurement strategies, provision waves, picking patterns, route configurations, storage location utilisation strategies) that can be adapted to specific production environments. This makes the planning process consistent, repeatable and faster.
• Parametrised MTM values: MTM parameters enable consistent working and movement times in planning. Predefined values allow complex workflows to be realistically mapped and compared.
• Modelling of different principles: The platform allows the mapping of various concepts such as direct provisioning at the assembly line, supply via supermarket / warehouse logistics, parts picking, as well as various tugger train and transport systems. This allows different scenarios to be quickly created and evaluated.
• Standardisation and comparability: Clear modelling and defined key figures create a transparent basis for comparing variants, identifying bottlenecks and deriving optimisation potential.
  Adaptability to variant diversity: Especially in cases of high variant diversity and changing parts lists, the tool solution enables rapid re-planning in the event of changes in the product mix, quantities or layout adjustments.

Potential benefits

• Higher planning quality despite complexity: Predefined building blocks increase the accuracy of forecasts and reduce manual errors in planning.
• Faster response times to changes: New product variants or quantity fluctuations can be mapped using plug-and-play model logic without extensive redevelopment.
• Transparent decision-making basis: Consistent models provide comprehensible criteria for investment and layout decisions.
• Improved resource efficiency: Optimised delivery routes and picking processes lead to shorter throughput times, reduced downtime and better utilisation of warehouses and conveyor technology.