flexis Integrated Production and Human Resource Planning
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Production planning from the viewpoint of optimized human resource allocation in terms of Hours Per Vehicle (HPV) efficiency
The structure of supply in the automotive industry distinguishes itself through complex, customer-specific products, which necessitates in-depth training for employees.
Automotive suppliers continuously invest a great deal in initial and advanced on-the-job training for employees, which leads to superior flexibility of production workforce in international competition. However, this workforce flexibility is usually being used only for reactive support, in order to be able to effectively implement the planned production program in the production hall. Cost-intensive workforce flexibility is therefore being used instead of planning the production program with integrated human resources in order to achieve a global optimum.
The potential of integrated production and human resource planning
Over the last years, flexis has successfully developed and deployed solutions for integrated production and human resource planning.
Slotting: All Customer Delivery Dates Under Control
During the order slotting process, realistic customer delivery dates are allocated and a buildable plan with regards to capacities is created. Shortages can be prevented during the customer delivery date allocation process by means of an ordered and leveled production plan. flexis facilitates a slotting process that accommodates plant capacities – including resource-dependent demand points. It is thereby possible to identify and book the optimal slot per order. Manpower requirements are also taken into consideration at this stage.
Balancing: Several Capacities in Sight
A balancing of order buckets occurs in the mid-term time horizon not only with regards to abstracted capacities, such as e.g. uniform distribution of vehicles with distance sensors, but also regarding the resulting manpower requirements. A vehicle outfitted with top quality features requires more manpower than the average vehicle. Taking personnel, assembly and line capacities into consideration results in a balanced and harmonized production plan, which cushions daily fluctuations in manpower requirements.
Sequencing: Exact Line Balancing of the Assembly
In the short-term horizon, an optimized and buildable production plan is created within the realms of sequencing. Capacity restrictions as well as restrictions and available flexibility resulting from human resource planning are taken into account.
In addition, load peaks and valleys are detected and prevented at the outset via a uniform distribution of these peaks and valleys during planning.The flexis solutions optimally support this planning. Capacity restrictions and excess capacity are automatically detected and balanced. The result is an optimization of the production processes in logistical terms and with regard to aspects concerning human resource allocation. This pays off in the form of significant control over HPV efficiency. In the future it will also be possible to temporarily move work along the assembly line when one station is overloaded with capacity while the following station has free capacity at its disposal.
The Benefits at a glance:
* Significant decrease in hours per vehicle
* Higher manpower flexibility
* Optimal production results
* High adherence to delivery dates
* Flexible manufacturing process
* Increase in employee motivation
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