Before
Client’s Challenges
Manual scheduling
Integrating ERP, MES & APS
Numerous process rules and restrictions
Lack of flexibility and responsiveness to changes
Poor visualization
After
Results with Asprova
Standardization of the scheduling process
Synchronization of production data between ERP, MES & APS
Compliance with all process rules and restrictions
Easy simulations of production schedules & what-if scenarios
Schedule evaluation and analysis – planned vs. actual
Inventory reduction
ABOUT THE COLLABORATION
Magna X Asprova
Magna, a leading global supplier to the automotive industry, operates two facilities in Czechia that produce plastic components for passenger cars, including bumpers, tailgates, grilles, and door sills. The production of these parts involves complex processes like injection molding, painting, and assembly, requiring the scheduling of dozens of machines and hundreds of molds—one of the most challenging tasks in the automotive sector. In 2012, Magna chose Asprova to manage this complexity by implementing a multi-plant scheduling system that addresses both factory-specific requirements and the extensive production processes and constraints at its two plants.
With Asprova’s advanced analysis tools and visualization capabilities, Magna can assess and optimize its production, both in the short and long term. Asprova schedules the entire production cycle for Magna’s two Czech plants in Liberec and Nymburk, synchronizing production data from SAP and MES. Magna uses Asprova to continually review production status, monitoring the production schedule against completed progress, and run additional what-if scenarios. Furthermore, Asprova improves resource allocation, optimizing staff assignments and production orders to respond to critical changes when necessary. Thanks to Asprova’s capabilities, Magna can quickly adapt to new customer demands or other changes, as the system takes all relevant parameters into account when rescheduling existing orders or scheduling new ones. With the push of a button, Asprova generates a revised schedule, delivering optimal production results in a short amount of time, ensuring optimal production lot sizes at all times.
With Asprova APS, Magna has reduced administrative overhead, improved cost calculations, improved insights into overall plant operations, and boosted scheduling efficiency by over 50%. The company has also cleaned up master data, reduced inventory levels of both WIP and finished goods, and successfully implemented just-in-time (JIT) and just-in-sequence (JIS) delivery.