In today’s fast-moving manufacturing environment production planning can either drive growth or create constant disruption. Many companies struggle with unstable schedules frequent replanning limited visibility into stock levels and overwhelming workloads for planning teams. The result is often a cycle of firefighting rising operational costs and missed opportunities.
This was exactly the challenge faced by one manufacturing organization before partnering with KORN CONSULT GROUP (KCG).
The Challenge: A Planning Process Under Pressure
Before the transformation the company’s production planning process was plagued by inefficiencies that affected daily operations and long-term performance.
Key challenges included:
- Inefficient production planning processes
- Unstable order handling and frequent replanning
- No frozen zone discipline
- Excessive workload for planners
- Limited visibility of stock before work order release
- ERP integration limitations
Without a structured planning framework planners were constantly reacting to problems instead of proactively managing production. Open production orders had reached an overwhelming 9,000 per week while planning cycles consumed between four and six hours for every plan created.
The organization needed more than incremental improvements. It needed a complete transformation.
The KORN CONSULT GROUP Approach
To address these challenges KORN CONSULT GROUP designed and implemented a structured digital and scalable production planning framework focused on creating stability visibility and control.
The approach combined operational excellence with digitalization through several key initiatives.
1. Establishing Planning Discipline
A new process was introduced to ensure all ERP orders were closed at the end of each monthly period. Historical visibility was maintained while keeping the planning environment clean and accurate.
2. Optimizing LOT Size Calculations
Demand patterns were analyzed using weighted consumption methods. Material costs packaging requirements and production constraints were incorporated into LOT size calculations to improve efficiency and inventory control.
3. Streamlining BOM Structures
Complex routing structures were simplified and semi-finished products were introduced where appropriate. This created better transparency and reduced planning complexity.
4. Integrated Production Planning
Planning was expanded beyond production requirements to include preventive maintenance considerations. This ensured that operational realities were reflected in every schedule.
5. Driving Digital Planning Excellence
ERP data analytics and digital planning tools became central to decision-making. Planners gained access to actionable insights that enabled faster and more accurate planning decisions.
Results That Delivered Immediate Impact
The transformation produced measurable results in a remarkably short period of time.
A 10-Day Frozen Zone Implemented
One of the most significant achievements was the implementation of a 10-day frozen zone that created schedule stability and reduced constant changes to production plans.
Open Production Orders Reduced by 83%
Open production orders dropped dramatically from 9,000 per week to just 1,500 per week within two months. This reduction improved visibility and significantly increased operational control.
Planning Time Reduced by 94%
What previously required four to six hours could now be completed in just 20 minutes. This massive productivity improvement allowed planners to focus on strategic activities instead of administrative tasks.
Leaner and More Effective Planning Team
Planning department headcount was optimized from 25 to 15 while improving overall performance and workload balance.
Stronger Operational Governance
No work order could be released without a component stock check creating greater reliability throughout the production process.
Smarter Decision-Making Through Early Warnings
An internal early warning system was introduced between shopfloor procurement and planning teams enabling faster issue detection and proactive responses.
Fewer Schedule Changes
Production schedules within the frozen period were reduced from 18 changes to fewer than three creating a far more predictable operating environment.
Before vs. After: A Complete Transformation
Before the project the company faced unstable schedules high workloads frequent planning changes and a lack of visibility.
After the implementation by KCG the organization achieved:
- Stable and reliable production schedules
- A 10-day frozen zone
- Faster planning cycles
- Improved workload management
- Lower operational risk
- Enhanced planning accuracy
- Active early warning capabilities
- Greater confidence across the organization
Building Sustainable Business Impact
The benefits extended far beyond production planning.
The company achieved:
- Lower inventory risk and reduced working capital requirements
- Higher on-time delivery performance and stronger customer satisfaction
- Increased planning efficiency and production capacity
- Greater operational stability and reliability
- Improved ERP readiness and higher-quality data
- Stronger cross-functional collaboration between planning procurement and shopfloor teams
By combining digital tools process excellence and data-driven decision-making KORN CONSULT GROUP (KCG) transformed production planning from a source of operational stress into a strategic business advantage.
Why This Success Matters
Great production planning is not about working harder. It is about creating the right structure leveraging accurate data and implementing processes that support consistent execution.
This project demonstrates how organizations can unlock significant improvements in efficiency productivity and operational performance when planning is treated as a core business capability rather than an administrative function.
The results speak for themselves: faster planning fewer disruptions better visibility and sustainable operational excellence.
Ready to Transform Your Production Planning?
If your organization is struggling with unstable schedules excessive planning workloads high inventory levels or limited operational visibility KORN CONSULT GROUP (KCG) can help you build a structured digital and scalable planning framework that delivers measurable results.