Prozessanalyse und Rahmenbedingungen für die Einführung des APS-Systems DUALIS in der Serienfertigung bei COLOP

Abstract

Series manufacturers such as COLOP are facing increasing planning complexity, shorter product life cycles, a wide variety of variants and strict deadlines, as well as frequent disruptions (machine downtime, material delays, staff availability). Although the existing ERP system provides the data basis, detailed planning is largely carried out manually and decentrally by planners. This requires a lot of effort, is heavily dependent on experience and offers only limited transparency. As part of a professional internship, COLOP has therefore initiated a proof of concept (PoC) for the implementation of an advanced planning and scheduling system in order to test its suitability, benefits and feasibility in a real-world environment. The COLOP company is being used to link together theoretical principles of production planning in series manufacturing. The actual planning processes were methodically recorded for each area, and the time required for detailed planning was also recorded. On this basis, a GAP analysis was carried out between the actual planning and the possibilities of a standardised APS. In a test environment, the master data and parameters were cleaned up or supplemented, optimisation groups and setup matrices were created, and scenario tests were carried out with real order data. In addition, requirements for the organisation and change management were formulated. The study confirms the fundamental suitability of the DUALIS APS system for COLOP. The system creates setup and capacity-based sequences, enables the consideration of scenarios and addresses central bottlenecks in current, experience-based planning. At the same time, the test phase clearly shows what prerequisites are necessary for optimised results. Success factors for the project include clean master data in the ERP system, uniformly defined planning rules, clear responsibilities for data maintenance and the early involvement of planners. The analysis results in concrete framework conditions for implementation. The work shows that ERP as the data backbone and APS as optimising detailed planning can together significantly improve planning capabilities in COLOP's highly varied series production environment, provided that clear rules, good data quality and effective change management are in place.

Date of Award	2025
Original language	German (Austria)
Supervisor	Gerald Schönwetter (Supervisor)