Setup planning optimisation for special-order products
Mathematical optimisation generates setup plans by plant, line and day, targeting 100% sales-plan fulfilment three days before shipment while cutting east-west transport costs.
- Client
- Manufacturer (Japan)
- Industry
- Manufacturing
- Market
- Japanese client
Key metrics
Challenge
Plans had to respect many constraints, including the sales plan, plant and line capacity and operating days. Supply and demand imbalance between the eastern and western regions also drove up transport costs.
Approach
Python with mathematical optimisation solvers (OR-Tools, CP-SAT, CPLEX and others) generates setup plans by plant, line and day, optimising across capacity, product priority, setup continuity and east-west transport costs.
Scope of work
- Constraint mapping: capacity, operating days, priorities
- Mathematical optimisation model
- Automated setup plans by plant, line and day
- Optimisation for east-west transport costs
Results
Plans now target 100% sales-plan fulfilment three days before shipment, curb the east-west imbalance to cut transport costs, and make production planning faster and better optimised.