"The capacity projection demonstrated by integrating production outputs into our simulations proves that our OEE is credible. We know that if we project an OEE of 75%, we will be able to achieve it. We have achieved it in the past."
Lean Manufacturing Engineer at Nexteam
Robin Delmas
What was your need in turning to Oplit?
Originally, we were looking for something like the loading capacity module of Oplit, which allows us to schedule and organize our site or group over the coming weeks or months, based on the incoming load.
Indeed, our machining division has 14 production sites with their own information systems and ERPs, which presents a daily challenge.
We also had sites with disparate capacity loading processes due to their history and the processes established at each of these sites. We sought to standardize all of this by deploying a common process and tool across all our sites.
We also needed a reliable and robust solution that could support us during capacity loading audits as well as help us achieve medals in Aerospace Excellence.
How did you operate before?
We had a lot of Excel files and they had some issues.
Indeed, as soon as we enter complex Excel files with formulas or macros, we know that maintaining these systems becomes very complicated. There is nothing more unstable than an Excel file. We had already made an effort to standardize by sharing these Excel files across different sites, but it has nothing to do with the Oplit application.
How did the implementation go on the first site?
We started with 3 months of implementation and testing on the pilot site of Marmande.
How and over what period of time did the other deployments take place?
We deployed to the other 14 sites within 6 months.
Method - 4 waves of deployment (one new wave for each business unit every 6 weeks)
Resources - 0.2 FTE at group level + 0.2 FTE per business unit
Data - A high level of responsiveness from IT resources was required
What facilitated the acceptance of the deployment? (POC)
The solution proved to be very easy to use
The use of the solution in meetings with site managers who gained a lot in visibility and anticipation capacity
The responsiveness of Oplit's teams
The ROI
What about the ROI after the POC?
Like any industrial project, we were asked to calculate an ROI for the solution. We calculated it in a very pragmatic way following the POC. We compared the time we spent on the old tool versus the time we spend on Oplit in relation to the tasks we were performing. Clearly, we are now much more efficient. This allows us to spend more time on high value-added tasks, such as creating hypotheses. We will consider scenarios for balancing load capacity, and spend more time on that than when we had to update the data and integrate new data.
In the end, it takes us 1 hour to create our plan, and 1 hour to onboard a new user. This changes everything!
What about the use of Oplit for your capacity load audits?
The use of Oplit during capacity load audits has significantly streamlined discussions with our clients. They see the robustness of the process - they see that we perform recurring simulations, record assumptions, and track our objectives. The discussions are of better quality.
We present to them via Oplit the share of load they represent for us, our capacity situation. We make some assumptions with our clients during the session and analyze the impact. This allows everyone to fully understand each other's stakes.
Today, we see Oplit as a strategic asset in our client relationship. To the extent that during the contract signing, we tried to add a exclusivity clause but you refused (laughs).
Did all the sites have the same issues / challenges / needs?
In a way, yes. I think it's important to emphasize that originally, the project was designed to be scaled across the group.
It is absolutely necessary to have a link with top management; it was very important for the tool to be accepted.
Then, all stakeholders at each site needed to see an interest because this is a process that can monopolize many managers during reviews. It was important for everyone to find an interest so that the deployment would be a success.
Did all the sites have the same ERP / data format?
No, the different sites accounted for about 5 different ERPs (SAP, Helios, Sage X3, Top Solid, Industria), and therefore some slightly different data formats.
Who were the stakeholders in most deployments?
The IT department that provided standard data exports for all sites.
A Supply Chain manager in each business unit who had the role of Key User and was the direct link with the Oplit teams.
Was there anyone outside the Oplit team who was managing the cross-functionality of the project?
Yes, indeed. He is a continuous improvement manager at the group level who invested 25% of his time on the Oplit project, and there was also occasional involvement from the sponsors (Director of Transformation, IT Director).
What is the advantage of having Oplit at the group level?
In summary, Oplit allows for harmonization and continuous updating of the capacity load process at the group level and is a reliable and adequate tool for capacity load audits.
All sites speak the same language, and each can navigate from one site to another and understand the upcoming plan and the associated assumptions.
This navigation capability also provides visibility on potential capacity load trade-offs at the group level.
Very significant gain in visibility at the group level to understand the capacity load situation from one site to another.
Navigation possible in 1 click between sites with always up-to-date data.
Identification of sites that are overloaded / underloaded in a given job and simulation of load transfer, thereby promoting the development of internal subcontracting, reducing delays, and identifying unnecessary investments.
Identification of resources and skills at the group level.
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customized
Les chiffres clés
1 hour
To create a load plan
1h
To onboard a new user
15 Deployments
In 9 months
About NEXTEAM
Nexteam is an integrated player serving the aerospace and defense sector with comprehensive expertise in metallic parts through 4 métiers:
machining
foundry
sheet metal work
surface treatment
Nexteam also includes:
8 countries - 18 locations - 3 design offices
+2300 employees
285 M € forecast 2023 vs 220M€ in 2022
1 CSR action plan
1 Cyber Security program
1 modernization program
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