Scheduling
Mapping digital tools in production: how to optimize your industrial processes?
28/01/2025
In a world where Industry 4.0 is redefining productivity standards, mapping digital tools in production has become a strategic lever. From data management with ERPs to industry-specific scheduling software, each tool plays a crucial role in optimizing processes, gaining flexibility, and improving overall performance. But how can you tell if your industries are well-equipped? And what are the consequences if they are not? This article details everything you need to know to effectively structure your digitalization.
The transition to smart production is not limited to acquiring new technologies. It involves a global vision: every area of your factory must be equipped with suitable digital tools that communicate with each other. Yet, many companies hesitate to digitalize certain key steps, such as planning or scheduling. This lack of adequate equipment can lead to inefficiencies, extra costs, or delays in the production chain. This guide will enable you to:
Understand the central role of digital tools in production.
Identify the technological solutions suitable for each area.
Conduct an effective mapping of digital tools to avoid the pitfalls of non-digitalization.
The fundamental role of the ERP: The cornerstone of digitalization
Every industrial digitization project begins with the implementation of an ERP (Enterprise Resource Planning). As a true foundation, the ERP centralizes and structures data from various roles in the factory, such as orders, stock, and financial flows. Here’s why an ERP is essential:
Data centralization: All critical information is unified in a single system.
Interoperability: The ERP feeds data to other software in the industrial ecosystem (planning, scheduling, production).
Enhanced traceability: Accurate tracking of production movements and logistics flows.
The industrial ecosystem: A digital solution for every profession
To effectively digitize a factory, it is crucial to identify the key professions and the digital tools dedicated to them. Here is a mapping profession by profession:
Engineering (R&D and product design)
Computer-aided design (CAD) or product lifecycle management (PLM) software allows engineers to design products faster while reducing errors.
Examples of software:
AutoCAD
SolidWorks
CATIA
Expected outcome:
Reduction of time to market
Better management of iterations and product revisions
Improvement of collaboration between design and production teams
Operational advantages:
Reduction of design errors and unnecessary iterations
Optimization of costs related to prototypes and physical tests
Improvement of communication between design offices and production
Consequences without digitization:
Design errors that can impact production and lead to delays
Additional costs due to late changes during production
Lack of coordination between teams
KPIs to follow:
Average design time per product
Number of modifications after prototype validation
Development cost per project
Success indicators:
Decrease in time to production
Reduction of prototyping costs
Improvement in the compliance rate of first productions
Supply Chain (Flow and organization)
Production Planning
Advanced planning solutions (APS) calculate the best production sequences to maximize resource utilization.
Examples of software:
Quintiq
Kinaxis
PlanetTogether
Expected outcome:
Optimization of production capacity and resources
Decrease in delivery times
Reduction of unnecessary stock
Operational advantages:
Better synchronization between customer demand and production capacity
Reduction of costs related to overstocking or stockouts
Decrease in transportation costs thanks to better planning
Consequences without digitization:
Difficulties in adjusting production in the event of demand fluctuations
Increased risk of overstock or stockouts
Loss of competitiveness against more agile companies
KPIs to follow:
On-time delivery rate
Stock turnover rate
Just-in-time production rate
Success indicators:
Optimized production capacity
Improved customer service rate
Decrease in storage costs
Scheduling
Industry scheduling software is specially designed to plan short-term operations in detail. These tools precisely define "what to produce", "when", and "with what resources".
Examples of software:
Ortems
Preactor
Oplit
Expected outcome:
Optimized planning of production resources
Reduction of machine waiting times and downtime
Improvement in on-time delivery compliance
Operational advantages:
Decrease in downtime on production lines
Better management of emergencies and priorities
Optimization of equipment utilization rate
Consequences without digitization:
Frequent delays in production schedules
Risk of underloading or overloading resources
Difficulties in reacting to unforeseen events and urgent requests
KPIs to follow:
Machine occupancy rate
Percentage of manufacturing orders delivered on time
Number of manual adjustments in the schedule
Success indicators:
Improvement in adherence to production deadlines
Reduction of costs related to unforeseen events and adjustments
Increase in flexibility in response to demand changes
Purchasing and supply
Purchasing software enables precise management of supplier relationships and contracts, while optimizing costs.
Examples of software:
SAP Ariba
Ivalua
Coupa
Expected outcome:
Reduction of procurement costs
Improvement of raw material delivery times
Centralization and automation of purchasing processes
Operational advantages:
Easier negotiation thanks to analysis of prices and purchase volumes
Reduction of errors and duplicates in orders
Better management of supplier relationships and contracts
Consequences without digitization:
Time loss in the manual management of purchases
Increased risk of supply disruption
Difficulties in negotiating competitive prices due to lack of consolidated data
KPIs to follow:
Supplier order compliance rate
Average acquisition cost per unit produced
Order processing time
Success indicators:
Decrease in raw material costs
Improvement in supplier service rate
Reduction in the number of disputes with suppliers
Production: Monitoring and performance
The monitoring of production is often ensured by MES (Manufacturing Execution Systems). These solutions enable real-time monitoring of the performance of each machine and operator.
Examples of software:
Wonderware (AVEVA)
Siemens Opcenter
Rockwell FactoryTalk
Expected outcome:
Improvement of manufacturing process efficiency
Reduction of unexpected downtime and breakdowns
Optimization of overall factory yield
Operational advantages:
Immediate identification of bottlenecks
Real-time monitoring of machine and operator performance
Anticipation of maintenance to avoid production stoppages
Consequences without digitization:
Difficulties in quickly identifying and resolving production issues
High risk of additional costs due to unexpected stoppages
Decrease in productivity and margins
KPIs to follow:
Overall Equipment Effectiveness (OEE)
Number of unplanned machine downtime incidents
Equipment utilization rate
Success indicators:
Increase in OEE
Reduction in the number of production interruptions
Improvement in production capacity without additional material investment
Focus on scheduling and planning software: is it worth digitizing?
Why digitize scheduling?
Planning and scheduling are the backbone of production. Without suitable tools, factories risk experiencing:
Production bottlenecks that slow down output.
Poor prioritization management.
Financial losses due to delivery delays.
Excessive stock levels and poor working capital management.
With an industry scheduling software, supply and production teams respond more quickly, make better decisions, and communicate more effectively. Moreover, resource allocation is optimized through powerful algorithms.
How to assess the success of digitalization?
Key questions to ask:
Can I easily adjust my production in case of a demand spike?
Are my machines operating at their full potential?
Can I simulate scenarios to avoid resource conflicts?
Is the time spent on scheduling optimized?
Are production priorities clear to everyone?
Positive responses to these questions confirm a successful digitalization.
Checklist for a successful digitalization of your factory 4.0
To assess whether your factory is ready to integrate digital tools, follow this checklist:
Do you have a solid ERP?
Do your critical business areas (planning, scheduling, production) use dedicated software solutions?
Have you identified the KPIs to monitor performance?
Is interoperability between your tools ensured?
A checklist like this can serve as a roadmap to modernize your industrial processes.
The mapping of digital tools in production is not just a trend; it is a necessity in a constantly evolving industrial world. Each job in your factory, from engineering to production, benefits from specific digital solutions that increase efficiency and reduce errors. The central role of the ERP, combined with high-performance scheduling software, ensures an optimized management of resources and flows. If your company has not yet fully committed to this path, it is time to take concrete measures. Enlisting experts in industrial digitalization, like those at Oplit, can help you succeed in this strategic transition.
