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CasaComplete Highlights for Production Controlling and Production Planning through a Digital Twin for planning and control:

 

Planning of all areas in the production environment along the timeline and with different variants. This includes cost centers, cost objects, cost types, and service types. Simulations can be performed based on the automatically calculated resource requirements derived from sales volumes.

With CasaComplete's Digital Twin, different planning assumptions can be maintained in parallel as variants without modifying live data in the underlying ERP system, allowing production scenarios to be displayed and compared with minimal effort.

For control purposes, not only plan vs. actual comparisons but also the more meaningful target vs. actual comparisons are available.

All planning-relevant data and structures are transferred from previous systems and automatically updated in CasaComplete.

All planning results can be transferred to the ERP system responsible for operational execution (e.g., SAP).

CasaComplete enables early identification of capacity requirements per period and workstation, allowing rescheduling or relocation to create a more balanced and efficient production process.

 

• Automated creation of a corporate bill of materials (BOM) from plant-specific BOMs

• Changes in work schedules and BOMs/formulations over time (e.g., reduced setup times from mid-year onwards due to new machinery implementation).

• Optimization of liquidity requirements by adjusting planning parameters in MRP-based production planning. These include inventory multiples, lot size, order interval, lead time, minimum stock level, and setup times.

• Production volume calculation from sales using MRP logic or, for simpler requirements, sales = production volume per period.

• WIP (work in progress) calculation for project-based and order-based manufacturing

• Determination of workload per cost center and activity type based on sales planning, corporate BOMs, and work schedules

• Calculation of intercompany demands, IC transfer prices, IC revenue, and costs

• Simulation of cost center planning per activity type. This allows the costs of primary cost centers to be adjusted to production plan requirements and the costs of secondary cost centers to be aligned with those of the primary cost centers.

• Personnel demand calculation for in-house and external staff for workload needs, with threshold definitions for the maximum number of in-house employees per qualification. This also serves as the basis for mid-term personnel planning based on qualifications.

• Automatic adjustment of shift models to the respective workload demand

• Clear and efficient cost center planning with fixed and variable costs, secondary costs, and relative figures. In one screen, cost and workload types as well as secondary costs are planned for a cost center. This serves as the basis for the above-described simulation and for determining cost rates (tariffs).

• Calculation of the manufacturing costs of each product from production planning, intercompany transfer prices in case of plant relocation, calculation of manufacturing costs in cost differentiation between marginal costs (material, production, overhead) and fixed costs across all levels and intercompany relationships, separate calculation of pricing results (transfer price minus manufacturing costs) across all plants. Only in this way can the marginal manufacturing costs and the fixed costs be displayed across all plants, and a contribution margin for the corporate group can be determined.

• Interplant product comparisons are thus easily possible in terms of their cost structure.

• Automated creation and processing of strategic project categories for project-based manufacturing. In doing so, the cost and workload structures per 1,000 currency units of revenue are automatically generated and can then be adjusted. They serve to map the cost and workload progression over time per 1,000 currency units of revenue in a category, thus enabling the determination of costs from revenue planning over time. This cost and workload progression is automatically adjusted to the planned revenue dates (invoicing dates) in planning.

• Quick bulk data changes of raw material, energy, and material prices in separate versions of planning assumptions to visualize their impact on cost rates, product costing, and contribution margins.

• Automatic determination of material overhead surcharges for product costing from cost center planning

• IC surcharges for materials in product costing are also automatically generated

• Procurement-related costs (for one customer, 26 different types of procurement-related costs) can be changed instantly through bulk data changes.

• Quick bulk data changes of personnel costs and external workforce costs in a planning assumption version to visualize their impact on cost rates and product costing.

• Definition of various planning assumptions stored as driver versions. This results in different scenarios that show the effects of driver changes on the business situation in all areas such as liquidity, P&L, WIP, and balance sheet.

• Agile planning with the ability to involve all cost center managers with clear guidelines in the planning process.
  At any time, manual planning in a sub-plan (e.g., personnel) can be compared with a simulated/calculated forecasted plan.
  Personnel demand calculated from sales figures and work schedules, BOMs, and project categories compared with manual planning by the cost center manager.

• Document planning assumptions at every level of detail

• Dashboards and reports tailored to the area of responsibility for regular cost tracking and control from CasaComplete SSOT (Single Source of Truth) for plan, target, and actual data. This ensures that in the management team, everyone accesses the same data for their analyses.
  These control information up to the foreman level can be easily and clearly retrieved in the form of target-actual comparisons and can be quickly adapted to the information needs of target audiences. The target costs represent the benchmark against which actual costs are measured. The target costs are the planned costs adjusted to the actual performance. (Example: If an assembly cost center was planned for 10,000 hours but only delivered 5,000 hours, only half of the proportional costs are compared to the actual costs as target costs).

• Data warehouse (BI tool) for all production- and machine-related data with simple options for direct evaluation and provision of data for analysis by other systems after data transformation.

• Additionally, evaluations of all production-related data can be easily created using pivot tables, the report generator, or directly with "Python embedded." All evaluations can also be displayed in the browser. The results can also be easily accessed with external tools such as Power BI or Crystal Reports.

• Before making a decision, CasaComplete can calculate/simulate various questions. As a result, all resulting consequences are displayed:

• Which manufacturing technology is the most economical?

• Which substitute materials can be economically used, considering the changed work schedules?

• What impact do new manufacturing processes have on production costs and personnel needs?

• How does rationalization at a workstation affect individual products and their contribution margins

Advantages​

• Cost reduction through timely planned utilization and coordination of provided capacities for machines and personnel.

• Reduction of production times through constant utilization based on existing or adjusted BOMs and work schedules or cost structures. However, this does not fully fit. Production times are only reduced if batch sizes are adjusted. Constant utilization is achieved by adjusting inventory levels.

• Control of scrap and rework based on product or project costing.

• Assessment of "make or buy" decisions

• Quantification of site relocations based on standard or custom calculations. For site relocations, work schedules and BOMs can be stored at the new location, and cost center planning can be created. Copy/paste from an existing site.