Production control 4.0

Improvement of costs, quality and speed through real-time data connection. 

Optimal control of production

Manufacturing companies are facing ever-higher customer requirements with regard to delivery times, changing assortments and/or number of variants and decreasing numbers of items per article. It should also be possible to react flexibly to changes at short notice. Whether a system is particularly agile can be determined above all in the event of high or low demand at short notice, e.g. in the event of heatwaves, the onset of winter, seasonal events or crises such as the corona pandemic.

Oftentimes, production does not manage to react quickly to short-term orders, changes, bottlenecks or failures. With the right concept for Production Control 4.0 and real-time monitoring of production, these challenges can be managed and flexibly responded to changes.

Why is production control so important?

 The better the interaction within the PPS system and the underlying IT system, the easier it is to avoid production stoppages and dissatisfied customers with the resulting costs and loss of image. Therefore, the goal should be to design the planning and control processes so that they are adaptable and a quick response time is possible.

An improvement in response times is primarily possible through real-time data connection and processing of the data in KPI dashboards. Data from machines, work parts and the warehouse are recorded via sensors. In the case of machines, for example, temperature, vibrations, noises, energy consumption and speed can be recorded. Changes in production parameters (exceeding or falling below a defined corridor), standstills, or quality problems are quickly recorded and can be remedied by taking measures to solve the problems.

It is not just the production processes that need to be proactively controlled and monitored. The intralogistics must also be set up appropriately through decisions on lot sizes and maintaining flexibility. In the future, companies want to avoid rigid production structures to meet market requirements for agility.

This can be seen, for example, in flexible cell production in the automotive industry. Instead of being dependent on the inflexible assembly line, automobile manufacturers increasingly want to rely on flexible cell production in the future. As a result, rigid conveyors no longer transport the body but in a highly flexible manner with the help of driverless transport systems.

Optimizing these processes and the appropriate degree of automation or digitization for your company must be at the top of the list of priorities. On the one hand, it is important to design the planning and control process as efficiently as possible and, on the other hand, to rely on transparent and digitally networked processes.

We’ll support you with production control

  • Planning and optimization of production control
  • Creation of a flexible and agile production control
  • Adapting the current control concept to changed framework conditions (new variants, ramp-up / ramp-down, etc…)
  • Create flexibility in new circumstances
  • Set-up time minimization / optimization
  • Reduce activities that do not add value
  • Lot size optimization
  • Determination of the optimal lot size for your production
  • Smoothing production
  • Avoid peak loads to create a balanced production
  • Selection of MES
  • Selection and introduction of a digital production control
  • Workforce planning

What is the task of classic production control, and what is the task of Production Control 4.0?

 In addition to production planning, classic production control is part of the PPS. The production planning specifies the processes in the medium to short term. The production control releases the orders based on this planning and monitors or secures the execution. It regulates the actual sequence of activities during order processing and terminates the short-term machine occupancy. The aim here is to implement the requirements of the higher-level planning as precisely as possible and achieve the specified target values (e.g. throughput times, optimal utilization of resources).

The foundation of a successful Production Control 4.0 is a holistic, coordinated and digital information flow. To achieve this, IT systems are used in production. In addition to the classic ERP system, a Manufacturing Execution System (MES) (link to MES) is used to monitor production, which combines machine and order data recording as well as quality management and personnel time recording. In the event of deviations in quantities, deadlines or quality, production control intervenes quickly and flexibly to correct it. Warehouse Management Systems (WMS) are used to control the materials in order to optimize warehouse and material supply processes based on real-time data. 


Success factors


The right concept for production control depends on many influencing factors and the underlying production system. Together with you, we develop optimization strategies for production planning and control. With the help of unique control strategies, we smooth and synchronize your production. If necessary, with our internal software development competence, we also have the know-how for tailor-made tools to design the material flow in your production optimally. In addition, we support you in the selection and implementation of an MES.

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