Fraunhofer Institute for Industrial Mathematics ITWMOur researchers develop models that enable us to precisely control material and goods flows in complex production processes. This allows us to increase throughput, reduce lead times, and optimally utilize production capacities.
Intelligente Steuerung von Materialflüssen – Frau sitzt vor einer Planungssoftware
A Challenge: Coordination in Uncertain Production Environments
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Intelligent Control of Material Flows in Complex Productions
Greater Efficiency Through Model Based Rough Planning With Models – Optimized Material Flow for Higher Throughput and Improved Adherence to Delivery Dates
Smooth production can only be achieved if materials and intermediate products are available in time for the next processing steps. However, machine downtimes, staff shortages, or other disruptions make planning difficult. It is particularly challenging to keep track of all dependencies in detail in large, multi-stage production networks involving many departments. This is especially important in order to make the best possible use of often limited capacities.
Our Solution: Rough Planning With Customized Models
However, it is often not necessary to replan the entire process in detail. We therefore rely on flexible, tailor-made models with a simplified view of the processes. This allows us to identify the need for action quickly and transparently, reduce planning effort, and lower the cost of data maintenance. In this way, we deliberately control material flows and avoid bottlenecks – even in complex production environments.
Practical Example: Optimization Using a Mathematical Model
In an industrial project with a long-standing partner, we have developed a mathematical optimization model that determines material flow on a daily basis. This allows us to maximize both the utilization of bottleneck resources and adherence to delivery dates. The operational plans for the individual production stages can then be derived from this rough planning.
We also take into account special requirements such as minimum and maximum material resting times. By embedding the model in comprehensive production planning software and connecting it to an ERP system, we ensure that the data remains up to date and manual maintenance effort is minimal. With this approach, we enable companies to efficiently control production, which increases performance while improving flexibility and responsiveness.
Schematic representation – graphic shows how bottlenecks in production are reduced through intelligent control.