The order export drops in
The weekly file from SAP is read straight in, and every line is matched to a product.
Human inputCase study 03 ยท Manufacturing
Canopies UK planned production by hand, from one spreadsheet and a wall of T-cards. GSD Lab built a working model of the factory floor that answers the question in minutes, and says plainly what is holding the week up.
Every week someone sat down with an order export, a stock report and what they knew about the factory, and worked out by hand what should be made. That knowledge was real and hard-won, but it only existed in one place, it took hours, and nothing behind it could be checked.
Moulds made it harder. Several products share the same mould, so two orders can quietly collide, and the only thing stopping that was somebody remembering. The question the business kept asking, and could never answer quickly, was simple: if we take this order, when can we actually make it?
So we built one. Every product, every stage, every mould and every person is in there, with the real minutes each job takes and who is allowed to do it. Off that model, the app answers the questions that used to need a morning: what has to be made, who is going to make it, and what is going to be late.
It started as a capacity calculator. It is now the thing the week is planned on, and each round of real use adds the next bit of how the factory truly works.
The weekly route
The weekly file from SAP is read straight in, and every line is matched to a product.
Human inputAnything already sitting in the warehouse is taken off before a single job is planned.
AutomaticEach job lands on a named person and a day, within their skills, their hours and the moulds available.
Automatic, with a human overrideCards print for the board, and anything at risk is listed with the honest reason why.
Floor outputWhat it took the guesswork out of
Two products that need the same mould can no longer be planned on top of each other without the app saying so.
Was tracked by memoryWork already covered by stock never reaches the floor, so the plan is what is genuinely left to make.
Was a manual cross-checkThe app says whether an order is short of people or short of moulds, because only one of those is fixed by working late.
Was a judgement callExtra hours are booked as the sessions the factory actually works, by name, not as a lump of spare minutes.
Was a rough estimateIf the plan only exists in somebody's head, it can be written down properly. Let's map how your work really flows and build from that.