Work centre load is visible in real time
Shows live utilisation across every work centre, so overload shows up before it becomes a bottleneck.
Multiple Work Centres
One work centre drowned in overtime. Another sat empty. Nobody saw it happening.
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The Setup
Inside the Operation
A supplier making machined and stamped parts for automotive customers, with production split across several work centres, each covering a different stage of the process. Some weeks, one work centre would run flat out on overtime while a nearby one had spare capacity the whole time, and nobody had a clear way to see it happening until orders started slipping.
24
Machines across 4 work centres
2 Shifts
a day, plus occasional overtime
1 Planner
Balancing loads by hand
The Problems
The Hidden Costs of Manual Scheduling
Without real-time visibility and structured planning, small scheduling issues quickly turned into delays, inefficiencies, and constant firefighting.
One work centre ran flat out on overtime while another sat idle - and no one could see the imbalance.
Load was never matched to real, current capacity, so bottlenecks built up unnoticed.
Overtime costs climbed on one line while spare hours went unused on the next.
Without a shared, real-time view, the mismatch only became obvious after the money was spent.
The Change
What Changed With Smart PPS
Work reroutes when one centre is overloaded
Sends operations to another available work centre automatically, no manual checking needed.
Shift capacity reflects what's really available
Breaks, overtime, and extra shifts are factored in, so capacity numbers are accurate, not assumed.
Estimated Impact
The Business Impact of Smart, Automated Machine Scheduling
Estimated ranges based on typical capacity balancing scenarios like this – not measured results from one specific customer.
20–25%
Idle time across machines and work centres
Fewer
Work centres running into unplanned overtime
Manual → Automatic
How overloaded work centres get rebalanced
Accurate
Shift capacity reflects real available hours, breaks included