DNP increases production with less changeover time thanks to Advanced Planning and Scheduling software

DNP Imagingcomm Europe is an international manufacturer of materials for print and imaging applications, including thermal transfer ribbons, photo materials, and solutions for ID and credit cards. Each product requires a specific combination of machines and settings. This means that the order in which production jobs are carried out can make a major difference.

Every time a machine needs to be reconfigured, production slows down. In an industry with tight margins, efficient planning is therefore essential to produce as much as possible within the available time.

Blue Green Solutions developed a custom Advanced Planning and Scheduling software application for DNP. Using a smart algorithm, the application helps DNP schedule production jobs more efficiently and reduce unnecessary changeover time.

Too dependent on Excel, too few options in Microsoft Dynamics

DNP previously worked with its own database and several Excel files. Two planners managed this environment and the related queries.

As a result, much of the planning knowledge was concentrated with a small number of employees. The process was difficult to transfer to others, while creating and adjusting the production schedule involved a lot of manual work.

At the same time, DNP was implementing Microsoft Dynamics as its new ERP system. However, the standard software did not provide the specific planning capabilities required for DNP’s production environment. Adding custom functionality directly to the core ERP system would also take considerable time and make the system more complex to maintain and develop further.

DNP therefore needed a solution that matched its specific production process, could be developed quickly, and integrated well with Microsoft Dynamics.

Advanced Planning and Scheduling software alongside the ERP system

Blue Green Solutions developed the Advanced Planning and Scheduling application with Mendix. Microsoft Dynamics remains the central system for production orders and related data, while the Mendix application adds the specific planning logic DNP needs.

“With Mendix, we were able to quickly develop a custom solution alongside Microsoft Dynamics and the MES. The ERP system remains the central foundation, while the Mendix application supports exactly what the planners need in their daily work. This combination of standard software and flexible customisation is a good fit for the organisation,” says Eric Weijers, CEO of Blue Green Solutions.

The application retrieves production orders from Microsoft Dynamics. A smart algorithm then calculates an efficient production sequence. It takes into account factors such as the characteristics of each order, its deadline, and the time required to reconfigure the machines.

The final schedule is sent back to Microsoft Dynamics and from there to the MES that controls the machines. This means the application does not become a separate software island, but fits directly into the existing IT landscape.

The main features of the APS application include:

• Changeover matrix: calculates how much time is needed to switch a machine from one product to another. This allows the application to schedule production jobs with similar settings directly after each other.
• Production planning: planners can define what they want to produce on a specific machine within a certain period. The algorithm includes these choices in its planning proposal.
• Gantt chart: provides a clear visual overview of which orders and product groups are scheduled at which time.

An efficient production sequence based on a smart algorithm

The application retrieves production orders from Microsoft Dynamics and uses this information to create a planning proposal.

A smart algorithm developed by Blue Green Solutions considers factors such as the material, required machine settings, and the deadline for each order. Based on this information, the system determines the most efficient order in which production jobs can be completed.

A changeover matrix calculates how much time is required to reconfigure a cutting machine from one product to another. By scheduling similar jobs together, DNP can reduce the number of time-consuming machine changeovers.

The proposed schedule is displayed in a clear Gantt chart. Planners can still make adjustments where needed.

More insight into planning, less production time lost

Blue Green Solutions developed the application in around eleven weeks. After just three weeks, the planners and Operations Manager were already able to review the first version and provide feedback.

The application was developed step by step and tested throughout the project by its future users. This made it possible to improve both the functionality and user experience during development.

Simplicity was an important principle. Microsoft Dynamics contains many different functions and screens. The APS application only shows the information and actions that planners need. This keeps a complex production process manageable in daily use.

With the new application, production planning becomes more transparent and less dependent on the knowledge of individual employees. The algorithm takes over a large part of the manual planning work and searches for a production sequence with as little changeover time as possible.

This helps DNP make better use of its available production capacity.

A stable core with room for customisation

With the APS application, DNP adds the planning functionality it needs without filling Microsoft Dynamics with company-specific customisations.

This gives the organisation a stable core system while maintaining the flexibility to support its unique production processes. Other custom processes can also be developed quickly and efficiently around the core software.

Are you also reaching the limits of standard software within your production environment? A flexible low-code application could be the solution. Our Mendix Experts are happy to explore the possibilities with you.

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