Production capacity planning: every decision affects the next

Start with the whole order

A cream and a lotion pass through pre-weighing, production and filling. They share a production vessel and a filling line, but need different pack formats. Switching between them requires a format change that occupies the line.

That links the decisions across the process. Finishing production earlier only helps delivery if filling can follow. Capacity planning must connect the route of each order with the equipment and people it shares with other orders.

Which batch should go next?

Keeping the current filling format avoids an immediate changeover. But what if the other product has the more urgent delivery? Saving line time can still leave the wrong order waiting.

PLEXecute considers delivery pressure and configured order priorities when selecting the next operation. Its default rule includes the work still required along the order’s remaining route. When comparing the assignments it finds, the standard planning behavior described here prioritizes avoiding delays, followed by delivery margin, then resource time and changeovers. The options examined depend on the configured rules and planning settings.

Check whether that choice can actually run

An urgent batch cannot simply be placed in the next gap. Its preceding work must be complete, suitable equipment must be available, and the required qualified people must have overlapping availability.

For filling, PLEXecute also checks the capacity needed to change format. Inserting a batch between existing assignments can require a change before it and another after it. A slot that fits the filling time alone may therefore be unusable.

See what one delay changes

The batches can progress in parallel on different equipment, but cannot use the same line at once. Follow the colors of the batches through the plan: the lotion finishes production while the cream is still filling, then waits for the line and its format change.

If the filling line is released later, pre-weighing and production can keep their places. The filling sequence and its required changeover move together, leaving less room before delivery. PLEXecute reserves each selected assignment and updates connected timing, so subsequent decisions use the capacity that remains.

Why a whole factory needs automated planning

The same trade-off appears wherever orders share equipment or people. Changing a sequence changes setup demand. Moving an operation changes availability elsewhere. A higher-priority order changes which compromise is acceptable.

Across a factory, these checks apply to many connected operations and must be repeated after relevant changes. Finding one empty slot by hand may be straightforward. Keeping track of its consequences for all the other orders is much harder.

Turn linked decisions into an actionable plan

Your team supplies process routes, durations, resources, priorities and fixed commitments. These inputs determine which possibilities the planner can consider.

PLEXecute connects them into order sequences, resource assignments, operation times and required format changes. Unscheduled work remains visible, so the calculated plan provides a concrete basis for decisions rather than a blanket delivery promise.

Check the outstanding operations and the margin remaining before delivery. You can then decide whether to change a sequence, adjust available capacity or revisit a delivery commitment.