Case Study: Mars Streamlines Manufacturing with Preactor APS (Now Opcenter APS)

The Challenge

Mars faced the challenge of manufacturing a large volume of products across a wide range of variations while managing the diverse demand from different markets. This complexity made scheduling accuracy a significant issue with their existing system. The need to handle these diverse demands effectively was crucial for Mars to maintain efficiency and competitiveness in its operations.

The Solution

To become leaner and more efficient, Mars sought to reduce stock levels and improve the accuracy of their scheduling. The solution they chose was Preactor APS and GMPS, now known as Siemens Opcenter Advanced Planning and Scheduling (APS) and Advanced Planning Ultimate (AP Ultimate). This system provided Mars with the tools needed to:

  • Use More Accurate Data: The implementation of Preactor APS allowed Mars to utilize more accurate and timely data, enabling better decision-making in scheduling and production planning.
  • Reduce Stock Levels: The new system helped Mars lower stock levels across their entire pipeline, representing considerable cost savings and more efficient use of resources.

The Benefits

The adoption of Preactor APS brought about several tangible benefits for Mars, including:

  • Lowering of Stocks: Mars successfully reduced stock levels across the entire pipeline. This reduction represented significant cost savings and more efficient inventory management.
  • Reduction in SKU Stock Levels: Specifically, Mars was able to reduce stock levels of one SKU from 10,000 pallets to 4,000 pallets, demonstrating the effectiveness of the new system in managing inventory more efficiently.
  • Lean Improvements: The changes led to leaner operations within Mars, supporting their goals of becoming more efficient and responsive to market demands.

Quotation

“Anyone involved in the pipeline has visibility of the entire pipeline, and this increases confidence and trust at every level. Preactor GMPS is driving internal behavior change, and we are definitely already seeing lean improvements. We have a long road ahead, but there are undoubtedly big benefits in the future.”

Conclusion The implementation of Preactor APS (now Opcenter APS) has been instrumental in helping Mars address its challenges with scheduling accuracy and inventory management. By leveraging more accurate data and optimizing stock levels, Mars has made significant strides towards becoming a leaner, more agile organization, setting the stage for continued improvements and future success.