Plastics & Films - planning that fits the plant
Sequence matters: color/material/tool cleanly sequenced
Separate MTS/MTO, see long procurement, include cleaning buffers. Don’t jump from white to black - sequence saves changeover time.
How we set it up
Excel dilemma and inventory paradox
Don’t go from white to black - each changeover costs time, material and often scrap.
MTS/MTO in parallel: standard grades to stock, specials to order - without clear rules it gets chaotic.
Raw materials/additives have weeks to months of lead time - late ordering risks downtime.
Typical planning problems:
- Campaigns with color/material/tool changes
- MTS/MTO alignment per product family
- Long procurement without clear disposition
- Volatile call-offs and irregular orders
- Single Excel lists - changes get lost
Sequence & changeovers
Order-dependent set-ups with cleaning times
Long procurement lead times
Raw materials/additives need weeks to months
Service level vs. inventory
Balance availability and carrying cost
Excel limits
System support instead of isolated spreadsheets
Planning support for plastics & films
From single Excel to system-supported planning
Set up sequence
Order by color/material/tool, include cleaning times.
MTS/MTO rules
Standard to stock, variants to order - per family.
Lead times & buffers
Plan early, set safety stock deliberately, not blanket.
Stable runs
Fewer start-up losses, reliable dates.
We put in place rules & parameters:
- Clear MTS/MTO criteria per group instead of one-off decisions.
- Sourcing by lead-time classes; buffers per class rather than blanket.
- Target service levels per item class - make availability measurable.
- Away from single Excel: put logic into the system, lists only for checks.
Secure Planning
Reliable dates
Fewer unplanned changeovers - sequence is clear.
Right-sized inventory
Safety stock where lead time is long.
Less afterwork
Less Excel cleanup, more rule-based planning.
Transparent service level
Priorities by class are traceable.