In manufacturing, production planning is often one of the most underestimated drivers of operational performance.
Without structured planning logic, stable processes and reliable stock visibility, companies quickly face:
- overloaded planners
- unstable schedules
- excessive firefighting
- and growing operational costs
A manufacturing company in Austria facing these exact challenges partnered with KCG to redesign and optimize its production planning processes, with a strong focus on stability, transparency and ERP readiness.
The Challenge
The organization struggled with:
- inefficient production planning processes
- unstable order handling
- lack of frozen-zone discipline
- excessive planning workload
- and poor visibility of material availability before workorder release.
Production schedules changed constantly, planners spent most of their time reacting instead of controlling, and ERP integration readiness was limited.
The company needed more than schedule adjustments. It needed a complete planning methodology transformation.
KCG’s Production Planning Optimization Approach
KCG introduced a structured production planning framework designed to stabilize operations while preparing the organization for future ERP integration.
The project included:
- implementation of a 10-workday frozen zone
- backlog handling and replanning methodology
- raw material stock verification before workorder release
- optimized lot-size calculation methods
- improved BOM structure setup
- integration of preventive maintenance impacts into planning
- and implementation of internal early-warning systems between shopfloor, procurement and planning teams.
One key focus was reducing unnecessary planning variability and creating clear operational rules that planners could follow consistently.
The result was a more stable, predictable and manageable production environment.
Fast and Measurable Results
The operational improvements became visible within a very short period:
- the 10-day frozen zone was successfully implemented
- open production orders were reduced from 9000 to 1500 per week within 2 months
- production plans became available in 20 minutes instead of 4–6 hours
- planners achieved significantly faster scheduling execution
- headcount in the planning department was reduced from 25 to 15 employees
- and no workorder could be released without component stock verification.
In addition, KCG implemented an internal early-warning system that improved communication and alignment between procurement, shopfloor operations, and planning departments.
Why Production Planning Matters More Than Ever
In modern manufacturing, production planning is no longer just an administrative activity. It is a strategic operational control system.
Companies with optimized planning processes achieve:
- higher operational stability
- faster reaction capability
- lower inventory risks
- improved production efficiency
- and better ERP integration readiness.
At KCG, we believe sustainable operational excellence starts with transparent, disciplined and data-driven planning processes.
Because the best production environments are not the ones reacting fastest to problems, but the ones preventing chaos through structured planning.