THE CHALLENGE

Missed Deadlines and Prolonged Throughput Times
HellBa faced challenges in maintaining consistent delivery timelines and minimizing lead times, which impacted customer satisfaction and operational efficiency.

Poor Capacity Utilisation
Without tools to accurately monitor and optimise resource usage, HellBa struggled with balancing capacity distribution of machine, molds, tools, and workers, leading to both bottlenecks and wasted resources. 

Intransparent Real-Time Progress
The absence of a connected system for capturing and reporting real-time progresses created visibility gaps, making it harder for HellBa to track ongoing processes and identify inefficiencies. 

Managing Diverse Customer Requirements
As a contract manufacturer, HellBa had to handle multiple production orders simultaneously, each with unique specifications, materials, and deadlines. This created planning complexities on prioritising, especially when different orders utilise the same resources.

Cross-Departmental Collaboration
As a supplier and machining expert, HellBa’s production process required seamless collaboration across departments. Disjointed workflows and communication silos often disrupted operations.

THE SOLUTION

To overcome these challenges, HellBa GmbH implemented planeus, a flexible and user-friendly production planning solution. Key features and outcomes included:

Cross-Department Sync of Orders and Requirements
planeus incorporates HellBa’s diverse production orders from different customers into a plausible and goal-oriented plan. The system allowed for easy cross-department tracking of customer requirements, deadlines, and adjustments, ensuring all orders were processed accurately and efficiently.

Resource Allocation and Conflict Management
planeus’ Conflict Radar helped HellBa eliminate production bottlenecks by identifying and resolving upcoming production conflicts. This ensures all production orders will be completed without delays, even when competing for the same resources.

Real-Time Feedback with Workbench Terminal
Using “Workbench Terminal”, planeus’s standalone shop floor data collection module, employees could update production process directly from their workstations, improving data accuracy and providing real-time context of order statuses for production managers.

Comprehensive Reporting and Dashboards
HellBa had an overview of their real-time and projected KPIs through customisable dashboards and detailed reports, providing instant guidance to optimise their upcoming productions.

Potential Check for Continuous Improvement
Potential checks were conducted onsite by planeus experts highlighted further optimisation opportunities, contributing to long-term improvements.

THE RESULTS

planeus delivered significant improvements for HellBa, including: 

• 50% increase in On-Time delivery rates
• 30% reduction in production time 
• 10% higher production capacity
• Opened opportunities to further scale up production

LOOKING AHEAD

HellBa GmbH continues to refine its operations with planeus, leveraging its insights and tools to drive further improvements. By managing diverse customer requirements more effectively and optimising resource use, the company is well-positioned to deliver high-quality products while meeting the unique demands of its clients.