"What if" based approaches, SCADA and EAM and ERP level integration and lifetime support. An example.
Current turbulent time for a production delivers a need to develop operational production planning, which will be able to reflect changes in realtime with actual situation in production. Additionally to reflection of changes this production planning routine should be able to change orders to production units with respect to situational changes.
These changes should be in timely manner delivered to the SCM module so main delivery plans and/or all SCM schedule are also amended if needed. On the other hand, sales plans and delivery schedules, final prices and logistic prices may change as well, so we need to be able amend production plans/delivery routes in a dynamic way. Additionally, feasibility is not to be forgotten - as sometimes rapid growth of sales volumes simply cannot be fulfilled with current production capacities.
In other words the sales/traffic team needs to be aware what is Available to Promise (ATP) - what is ALREADY available to promise/Capable to Promise - what CAN be produced until certain time and is not already blocked/promised to any client.
Moreover - to properly ask the question you need to know at least half of the answer - i.e. when we will raise staff and management awareness about reality - it will significally decrease stressful situations and reputational losses.
(example - fire in the production hall with 50% percent capacity decrease for a week).
Why synchronization between produciton lines/units is needed? because we have a lot of equipment types and lines, all equipment has regular maintenance windows and sometimes emergency maintenance occurs. Additionally, when the workload is close to the maximum capacity the maintenance free windows are smaller.
Therefore to maximize the output of the whole system we need to redistribute the production volume so it is distributed equally between production lines and we no not have nor idle times neither overload. This will make the production curve smoother and the production will be more rhythmic. This is basically Just-in-Time production model which is succeeded with Lean Manufacturing. Thus this will resolve stresses with fake delivery volumes and will show realistic picture of the production capacities online. Also, when any emergency situation occurs, and we need to change the production plan - the system will definitely include feasibility study whether the plan it still DOABLE.
Once the through business process and routine is established and in place the BI will allow to see the total sales plan feasibility, completion rate and quality parameters. Additionally after some minor analysis there will be clearly visible bottle necks and points to improve the SCM. With working mathematical model in place Ferrexpo sales and traffic managers will clearly see in real time from the interface information about actual sales plan FEASIBILITY, actual FULFILLMENT by production, quality, shipping and delivery points and volumes. If the plan is not feasible under current circumstances manager will see clearly quantity due and what product is affected. With this information he is early aware and will take appropriate actions with clients or redistribute the storage capacity to cover the difference.