Case Studies
Trusted by Stellantis, Grendene, Malwee, Polenghi, Premier Pet, Dana, Unipac, Mercur, Bartira, Peccin, and more.
Plan and Schedule Adherence in Manufacturing
Adherence measures the degree to which execution matches the plan or schedule. It evaluates both execution quality and plan quality simultaneously. Every deviation is an error — but not always the operation's fault.
Build to Plan (BTP)
BTP = Volume × Mix. Volume = Total produced ÷ Total planned. Mix = Σ min(produced, planned) ÷ Σ planned per product. Excess production of one item never compensates for shortage of another.
Build to Schedule (BTS)
BTS = Volume × Mix × Sequence. Sequence is evaluated relatively — a single skipped order does not penalize the rest of the queue.
Probabilistic Execution Model
Execution depends on: Material, Machine, Tooling, Operator, Quality. Overall probability = product of individual probabilities. At 95% reliability each: 0.95⁵ = 77.4% overall adherence.
Operational Contract
A validated plan (agreed between planner and supervisor) transforms the schedule from an imposition into a contract, reducing predictable conflicts.
Root Cause Categories
8 categories: Material, Machine, Quality, Operator, Priority Change, Tooling, Scheduling Error, Other. "Scheduling Error" is a valid root cause — the plan itself can be the source of deviation.
Read the full interactive article →