Before
Customer‘s Challenges
Manual scheduling using ERP and Excel
Unrealistic production start and end times
Push production
High inventory levels
Lack of delivery reliability
No process synchronization
Production lead time: 6-8 weeks
After
Results with Asprova
Scheduling is now automated, standardized, and independent of individual staff
Realistic production start and end times
Push processes are eliminated through effective bottleneck scheduling
Inventory levels are reduced by 50%
Detailed and synchronized sequence scheduling for all resources
Reliable delivery date commitments
Production lead time is cut by over 60 %
Simulation capabilities for all current and planned orders
Increased resource efficiency
Orders can be prioritized as needed
Potential issues are identified early through dynamic simulations
Switching from a push to a pull system has transformed our operations, cutting lead times from 6–8 weeks down to just 2–4 weeks.
ABOUT THE CUSTOMER
Kemmer Hartmetallwerkzeuge
Founded in 1974 in Wildberg, Germany, Kemmer Hartmetallwerkzeuge specializes in the production of specially coated cutting tools. In 1993, a production facility was established in Zella-Mehlis, where all turning and milling tools, as well as necessary tool holders, are manufactured. Offering a wide range of catalog products and customized solutions, the family-owned business has been scheduling its production with Asprova since 2011, delivering innovative solutions for the metalworking industry.
ABOUT THE COLLABORATION
Kemmer x Asprova
Before implementing Asprova, Kemmer operated according to the push principle which led to long lead times, high inventory, and frequent overproduction due to uncertainty. Scheduling relied on Excel lists and their ERP system, which couldn’t handle the complex, multi-step processes or multiple machine types involved. The scheduling approach couldn’t deliver a comprehensive solution or reveal underlying issues. It created unrealistic start and end dates, missed delivery targets, and made it impossible to synchronize processes effectively.
With Asprova, Kemmer now runs a pull-based, bottleneck-driven system that aligns production schedules with actual capacity. Asprova integrates with their ERP (ABAS), importing production orders and routings, while setting up critical process and scheduling constraints beyond ERP capabilities. Scheduling now accounts for finite resources like machine and personnel availability, process times, and buffers.
Asprova’s automated scheduling calculates precise delivery dates and sequences for each job, dynamically adjusting for delays and disruptions. The system also produces a detailed sequence schedule for each resource, factoring in machine capabilities and alternative routing. This includes the CAM process, essential to production, which considers the availability of CAM staff so production can launch seamlessly with the necessary machine programs in place. With these improvements, Kemmer has cut lead times from 6–8 weeks down to just 2–4 weeks.
Sequence scheduling for each resource is clear, meaningful, and reliable, which has greatly reduced scheduling workload and freed up time for other value-added tasks. Last-minute 'firefighting' is now rare.
Gallery
Project Team (left to right): Mike Peter (Production Scheduler), Raimund Kemmer (Managing Director), Thomas Engelhaupt (Project Staff)
Asprova Workshop (left to right): F. Weiß, G. Körtvélyessy & V. Lübke (Asprova), M. Peter & T. Engelhaupt (Kemmer)
On-Site Asprova Workshop
CNC Machining Center
Deep Hole Drilling Machine