Automation of production workflows: Planning
Manufacturing companies must manage daily challenges related to resources, delivery times, and product quality. Rigorous production planning directly influences costs, execution times, and customer satisfaction. More and more organizations are seeking ways to automate in order to eliminate bottlenecks, human errors, and lack of predictability. Find out what modern production planning involves, how digitalization with xTrack MES helps, and what steps are needed to implement this solution. By going through the guide, you will quickly understand the benefits of adopting production planning software and its impact on operational processes.
What does production planning mean?
Production planning means defining how the team will fulfill orders, with what resources, and in what sequence, so that the workflow remains smooth. This process involves making clear decisions about machine scheduling, staff allocation, and raw material management in order to achieve the objectives set by management.
In practice, planning requires identifying the correct quantities of raw materials, ensuring workforce availability, and synchronizing work steps with the delivery deadlines promised to customers. In a food production factory, for example, scheduling hours becomes an activity of utmost precision to respect expiration dates and ensure the safety of the products.
What are the limitations of traditional planning methods?
Many managers still rely on Excel spreadsheets, paper forms, or classic notebooks for daily scheduling. At a low order volume, such methods may seem sufficient. However, once product diversity or process complexity increases, these simple tools can no longer support the need for flexibility and speed.
Another common obstacle is the difficulty of communication between the planning team and the execution team. Without a centralized data flow, the risk of misunderstandings grows, and delivery time estimates become inaccurate. Many managers have noticed that such systems slow down reactions to priority changes or unforeseen events.
Why automate production planning?
Digitalizing production brings transparency, speed, and control over the planning process. A modern MES (Manufacturing Execution System), such as xTrack MES, organizes data in real time, automatically adjusts schedules, and provides a complete view of resources.
Through automation, the software correctly allocates machines and employees, taking into account parameters such as delivery deadlines, technological requirements, or customer priorities. If, for example, an unplanned absence occurs or a machine breaks down, the system quickly recalculates the schedule and proposes alternatives. This way, managers can provide customers with realistic estimates, reduce bottlenecks, and better control costs.
A MES application eliminates redundant steps and quickly generates GANTT charts, useful for visually mapping production stages. Companies that have switched to software immediately notice reduced downtime, less waste, and greater predictability.
Steps for automating production planning
1. Analyze existing processes
Map current workflows and identify where delays, duplications, or lack of synchronization between teams occur. For example, note if order intake takes too long or if equipment scheduling requires frequent manual intervention. Check how the team handles last-minute changes, how planning is communicated to staff, and what main difficulties operators or supervisors report. This step ensures clarity about real needs and forms the basis of any digitalization project.
2. Set concrete objectives
Focus on measurable results, such as reducing machine setup times, increasing delivery punctuality, or lowering raw material stocks. For serial production, set the objective of optimizing scheduling so that no order exceeds its fixed deadline.Involve department managers, key operators, and IT staff to gain a complete perspective on challenges. Practical example: in an automotive components company, the technical team requested real-time traceability for each production batch to quickly anticipate possible deviations.
3. Choose the right software solution
Modern MES solutions, such as xTrack MES, offer dedicated modules for planning, monitoring, and reporting. Make sure the software integrates easily with the ERP, WMS, or other applications used in the company. xTrack MES, for example, connects with the xTrack WMS system or with POD and TMS modules.Check whether the application allows automatic adjustments when problems occur, such as machine incidents or changes in customer requirements. Often, manufacturers prefer solutions that include intuitive GANTT charts and support for specific parameters, such as processing times or technological sequences.
4. Configure the system and train the team
Customize the planning module according to the specifics of the activity: product type, batch size, available resources, and internal prioritization rules. Load all upcoming orders, define machine setup times, add relevant constraints, and assign the correct order in GANTT charts.Organize training sessions for the entire team involved, both planners and operators. A smooth transition to digitalization reduces resistance to change. Show employees concrete examples of how they can quickly resolve unforeseen situations directly in the application.
5. Monitor, adapt, and continuously optimize
After implementing the solution, track key indicators: rate of on-time orders, productivity per line, or machine utilization. Use system-generated reports to identify areas where processes can be improved. If repeated delays occur, adjust planning based on feedback received from the team.
How does the automated planning module in xTrack MES work?
The xTrack MES solution, developed within a project co-financed by the European Social Fund, provides complete functionalities for scheduling, monitoring, and optimizing production. This system collects real-time data on equipment, inventory, and personnel, enabling efficient planning of all technological stages.
By entering relevant parameters (quantities, deadlines, special requirements), the application generates detailed schedules and automatic updates in case of changes. GANTT charts clearly display the sequence of operations and facilitate collaboration between the departments involved in production.
xTrack MES allows full integration with storage and distribution modules. You can track the status of each order, quickly identify bottlenecks, and immediately generate alternative scenarios. If incidents occur, automatic notifications help the team adjust the workflow without prolonged interruptions, strengthening collaboration between planning and execution.
The real benefits of automating planning with xTrack MES
Organizations that implement a dedicated system quickly notice several clear improvements:
➡️ Optimal resource allocation: The software automatically suggests the most efficient way to use equipment, teams, and raw materials.
➡️ Elimination of human errors: Mandatory parameters and automatic notifications reduce the risk of omissions or double scheduling.
➡️ Accurate delivery time estimates: Managers can provide clients with precise new deadlines whenever unforeseen changes occur.
➡️ Complete visibility: All stakeholders have access to updated data on processes, resources, and order progress.
➡️ Reduced costs and execution times: Automation lowers the risk of interruptions, optimizes the use of space and resources, and supports increased profitability.
Integrating xTrack MES into the company’s digital workflow
Adopting xTrack MES ensures complete connectivity between departments. The system integrates with warehouse management solutions (WMS), transport management (TMS), delivery tracking (POD), and maintenance systems (PMS). This synchronization provides full traceability and control across the entire supply chain (SCM – Supply Chain Management).
Companies in continuous or mass production industries, such as MTS (Make to Stock), leverage digitalization to increase flexibility and adaptability. A study conducted on three automotive firms showed that integrating MES with WMS reduced batch transition times by up to 30%.
In the long run, organizations develop a culture of continuous improvement, adapt more easily to market changes, and can quickly adjust processes when challenges arise, such as absenteeism, equipment failures, or demand fluctuations.
Automating planning with xTrack MES gives you complete control, predictability, and efficiency in production processes. You can organize schedules, resources, and orders with the confidence that each stage follows established rules. The Axes Software team responds quickly to requests and can explain every function of the automated planning module, including integration scenarios with ERP, WMS, or TMS.
Adopt technology responsibly. Respect principles of security and confidentiality, and manage company changes transparently. This approach supports collaboration and efficiency, regardless of the size or specifics of the factory.
