The automotive supplier Forvia (formerly Faurecia) undertook in 2022 to change its planning methods, adopting dynamic, high-frequency optimization of its workshop production plan (every 5 minutes, accounting for all business and operational constraints).
A Breakthrough in Planning
PlaniSense, in partnership with EURODECISION, reimagined the planning process at Forvia, replacing a rigid approach with a dynamic, optimized management system. This new method enables better responsiveness to unforeseen events and production optimization aligned with actual demand, ensuring more efficient resource use and a feasible schedule.
Ergonomics and Quality
At the heart of the solution is a combination of ergonomics, planning quality, and decision support. Using advanced mathematical optimization methods, it analyzes the context to propose optimized production plans. Planners benefit from an intuitive interface that makes it easy to adjust the tool’s proposals.
POC Validation and Deployment
EURODECISION’s LP-Scheduler optimization engine was integrated into PlaniSense’s Production Planning module. After completing a pilot on the plastic injection workshop in Tarazona (Spain), the tool was deployed across 12 Forvia group plants (France, Spain, Turkey, Germany, Poland, the United States, and Mexico). The goal is to reach 30 plants by the end of 2024.
Quantitative and Qualitative Results
Forvia sites equipped with the solution have observed significant improvements:
- 20% reduction in format changeovers
- 20% reduction in plastic waste
- 20% reduction in work in progress
- 4% improvement in OEE
- 50% reduction in internal shortages on assembly lines
At a qualitative level, the solution has enabled productivity gains, improved responsiveness, increased reliability, and improved collaboration and harmonization within the Supply Chain.
