Success Stories
DUPONT COMPANY - INDUSTRIAL MANUFACTURING
DuPont, a producer of synthetic fibers, was not satisfied with the schedules produced by its current scheduling system. The system could not take advantage of all the options on the production floor. For example, the existing system did not exploit the capability of some machines to produce two distinct fiber products simultaneously, at variable levels of throughput. Therefore, client was unable to fine-tune its production quantities. Attempts by internal and external consultants to add this functionality to the scheduling system resulted in unusable solutions.
The client decided to try a new approach and engaged Quantum Leap. There were two stages to this particular manufacturing process. The first stage produced raw material on one of three machines. The raw material then fed into connected spinning machines to produce one or more products. The scheduling system needed the ability to batch and schedule the production of the raw material, and then schedule the spinning machines to produce only the demanded quantity of particular fibers. To add to the complexity, the production crew had specified that certain fibers be produced on particular machines.
Quantum Leap's scheduling system provides substantial flexibility, allowing many day-to-day occurrences to be incorporated into the system. For example, one can alert the system when a machine is out of service, so that the schedule is optimized for the currently available configuration. The layout of the production floor is described in a data file, so that the client can update it when required. Using this feature, the client plans to use the system to schedule production at similar plants.
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