Planning Variety Production Using the Example of Chocolate Manufacturing

Industrial Manufacturing Presents Companies with Numerous Challenges, Particularly Regarding Efficiency, Cost Optimization, and Resource Utilization. Batch Production is a Proven Method to Specifically Improve These Aspects. Products with Similar Properties and Production Requirements are Manufactured in Successive Batches to Minimize Setup Times and Material Losses.

Characteristics of Unoptimized Series Production

In classic series production, different products are produced one after the other without targeted coordination regarding the similarity of materials or process requirements. This leads to inefficient processes, reflected in frequent setup times, as machines need to be retooled for each new product, causing time and cost. Additionally, high material consumption arises from non-optimized transitions between product types. Longer lead times are also a problem, as delays occur due to waiting times between production batches. To respond to production fluctuations, unnecessarily high inventory levels are required, necessitating larger buffer stocks.

Variety Production: Planning Related Products Together

In contrast to uncoordinated series production, batch production focuses on grouping products with similar properties. The goal is to enable the longest possible production runs without machine changes. The advantages of this strategy include the reduction of setup costs through longer production intervals within a batch, more efficient material use due to fewer losses during product changes, lower production costs through optimized machine run times and reduced downtime, and greater flexibility as production planning can be aligned with market demand and seasonal fluctuations.

Chocolate Production as an Example of Optimized Variety Production

Chocolate production is an excellent example of optimized batch production. Here, products with similar recipes and production processes can be grouped into series, making the entire production more efficient.

Criteria and Their Optimization Effects

Chocolate products can be grouped according to various criteria. Products with a similar cocoa base, such as milk chocolate, dark chocolate, and white chocolate, can be produced together. Varieties with nuts, dried fruits, or caramel should also be produced together to minimize production changes. Chocolate bars, bars, or pralines have different requirements for molds and packaging, and similar packaging sizes and materials facilitate logistics and reduce setup effort. In addition to product properties, production-technical characteristics can also be used for batch-specific optimization. In our example of chocolate, the size or capacity of the available conches can be chosen as a planning factor.

Batch production can realize several optimization effects in chocolate production. Fewer cleaning and setup times are particularly minimal when switching between products with identical base masses. Raw material utilization is optimized as the same ingredients are processed in large quantities, reducing purchasing costs and minimizing material residues. Efficient inventory management is enabled through coordinated production plans, allowing raw materials to be ordered and stored as needed. Increased machine run times are achieved through longer production cycles without retooling, improving capacity utilization. With the aforementioned approach, considering the conche size in our chocolate example, a possible optimization measure is to choose the batch size in production as a single or multiple of the available conche volume.

Variant Production (Complex Products): Pralines

While simple chocolate bars and bars have relatively homogeneous production processes, pralines are an example of more complex variant production. Pralines often consist of several layers, fillings, and decorations, requiring differentiated planning. Nevertheless, efficiency gains can also be achieved through batch production. Pralines with similar fillings are produced together, and tempering is optimized by producing pralines with the same melting temperatures and cooling times in one series.

Software-Supported Production Planning

Digital production planning offers significant advantages over manual planning methods. By using Fekor, the following optimizations can be achieved: Automated production planning uses intelligent algorithms that analyze production capacities and control the optimal production process. Real-time monitoring enables continuous recording of machine and material data to identify bottlenecks early. Flexibility in production changes is achieved through quick adjustments without significant retooling losses. The error rate is reduced as digital planning minimizes human planning errors and ensures optimal resource utilization.

Fekor is one of our digital solutions that optimizes production planning in the manufacturing industry through modern technologies. By using software solutions, manufacturing processes can be planned and controlled more efficiently.

Product Group Management

A good example of a more specific measure for production optimization with Fekor is product group management. This allows your products to be grouped and planned together based on their properties. Advantages of this method include optimized inventory management, as raw materials and semi-finished products are managed more efficiently. This also easily achieves reduced capital commitment by avoiding excess inventory and improved production utilization, as machines and labor are more evenly utilized.

Summary

Batch production is an exciting application for our solutions to optimize production planning, even beyond our example in chocolate production. By specifically bundling similar products, costs can be reduced, lead times shortened, and material losses minimized. Digital tools like Fekor and the tetys MES help further optimize these processes and increase your company's competitiveness.