Roadmap to Industry 4.0:
Planning & Scheduling in the personal & home care industry
Implementation of a new software for production planning & scheduling
Established in 1977 Madel Spa, is a leading Italian manufacturing company specialized in products for home & personal care.
Madel’s mission is the capability to create high-quality and environmentally sustainable products. The company vision can be summarized as follows: to provide innovative and valuable products to consumers, to make daily life easier while being respectful of our environment.
Madel manufactures and distributes more than 300 finished products, to meet the most diverse commercial requirements of its partners and
the various needs of end consumers around the world .
The company is focused on three main business areas: detergents and laundry additives, home care cleaners and beauty care products.
A longtime and valued partner to Italian most important distribution chains, Madel can count on a pervasive diffusion on the domestic market. The company is also expanding in the foreign countries, where it sells more than 10% out of its total revenue and is developing a sales strategy to further expand its future presence, through its subsidiaries Madel CZ and Madel International
Prior to implementing COMPASS, the planning and scheduling process was supported by the ERP software SAGE X3 and by the extensive use of Excel spreadsheets, but the situation had been considered far from ideal for a long time. Finally, in 2015, the company acknowledged it could no longer postpone the implementation of a planning & scheduling application. Company growth had made inevitable the replacement of the spreadsheets, which had become time consuming and inaccurate in result. “The implementation of an integrated planning and scheduling software had become a mandatory step, at least to upgrade the current off-line tools” says Guido Zanoni, MADEL IT Manager “Another objective of the project was to improve functional integration within the company, making the planning decisions more transparent and shared within the organization.”
The improvements expected by the company can be summarized below :
Improvement in on-time delivery and total lead time indicators
MADEL’s planning model is based on a Make To Stock approach, which is typical in the consumer product maket.
As a result of the project, COMPASS software, integrated with the ERP SAGE X3…
“Soon after COMPASS go-live we have achieved real benefits: the planners are able to run simulations and rapidly evaluate alternative scenarios to respond to unexpected fluctuations of market demand . The Dynamic Sequencing function has led to optimize set-up and increase productivity in the short-term. The Master Production Schedule has improved visibility in the mid-to-long term and has allowed to automatically adjust inventory levels of finished products accordingly to market seasonality and marketing promotions.” reports Guido Zanoni