Produktionsplanung im Elektromaschinenbau

In electrical engineering, project‑based design, workshop manufacturing, batch processes, and assembly come together under one roof.Multi‑level bills of materials, numerous subassemblies, and a wide range of production resources lead to complex interdependencies.Typical challenges:

decreasing batch sizes with increasing product variety
late changes in engineer‑to‑order environments
parallele Steuerung von Werkstatt-, Batch- und Linienfertigung
parallel control of workshop, batch, and line production
lack of transparency regarding bottlenecks and actual lead times

Without integrated APS planning, local optimizations, buffer times, and high coordination effort arise – with direct impact on lead times, on‑time delivery performance, and capital tied up.

Nahaufnahme von zwei integrierten Schaltkreisen auf einer Leiterplatte mit sichtbaren Leiterbahnen

Your challenges in production planning in electrical engineering

Market requirements and product variety

Variant manufacturing with decreasing batch sizes, short delivery times, and frequent changes – including in engineer‑to‑order environments.

Coordination of complex bill of materials

Synchronization of production and assembly orders across multi‑level bills of materials with numerous subassemblies.

Different manufacturing principles under one roof

Workshop manufacturing, batch processes (e.g., furnace processes), flow production with and without buffers, as well as flexible assembly areas.

Multi‑dimensional capacity constraints

In addition to machines and personnel, mandrels, molds, heating capacity, test adapters, pallets, inner and outer casings, or other production resources limit production capacity.

Nahaufnahme eines großen Metallrads mit mehreren Speichen in einer Werkstattumgebung

Why APS4EM for the electrical engineering industry?

APS4EM is a specialized planning solution for the complex requirements of the electrical engineering industry.All relevant constraints – machines, personnel, production resources, energy, and batch processes – are fully modeled and considered in an integrated planning run.

Full representation of all bottlenecks and secondary constraints
Algorithmic bottleneck optimization within a consistent overall plan
Feasible, stable plans without the need for local adjustments
Reduction of buffer times and coordination effort
Minimization of lead times while simultaneously reducing capital tied up
Setup and batch optimization, including AI support
Smoother production with a longer planning horizon

Semi‑professional planning solutions often cannot integrate all constraints.Local planning by team leaders compensates for these gaps – but with buffer times, short planning horizons, and suboptimal bottleneck utilization. APS4EM replaces this structure with algorithmically optimized, end‑to‑end planning.

Ihre Vorteile mit APS4EM

Targeted assignment of operations and machines

Performance‑based and resource‑driven assignment according to optimization criteria.

Integration of engineering and drawing milestones

Improved scheduling reliability in both rough‑cut and detailed planning.

Early detection of missing parts

Automatic validation with every plan adjustment.

Stable production with high employee motivation

Extended planning horizon with fewer short‑term changes.

Transparent workforce planning and control

Reduzierte Personalkosten durch exakte Zuordnung und Transparenz bei Über- und Unterauslastung.

Energy‑optimized production

In Verbindung mit Energiemanagementsystemen: Minimierung von Energiekosten und Lastspitzen.

Optimized batch and furnace processes

Maximale Auslastung bei gleichzeitiger Minimierung von Wartezeiten.

AI‑supported optimization

Intelligente Rüstplanung, Personaleinsatzoptimierung und Steuerung von Fertigungshilfsmitteln.

Planning architecture of the APS4EM tool suite

Capacity planning over mid‑term horizons
Load leveling and bottleneck identification
Early capacity adjustments and delivery date validation
Planning of repair and ad hoc orders
Reduction of inventory levels through stable capacity management

Realistic start times for setup, production, and maintenance
Automatic assignment to workstations and teams
Continuous optimization in the event of disruptions
Precise integration of short‑term delivery date requests
KI-gestützte Optimierung von Rüstzeiten und Fertigungshilfsmitteln
Integration of energy and spot markets with a connected EMS

Planning based on qualifications and availability
Synchronization of workforce and machine capacity
Dynamic response to disruptions
Transparent basis for decision‑making for management
Efficient real‑time communication

With APS4EM, you can plan complex electrical engineering manufacturing in an integrated and future‑proof way.

APS4EM covers all relevant technologies in electrical engineering – from sheet metal processing, winding, and furnace processes to resin and oil filling, as well as testing and assembly processes.The solution is suitable for manufacturers of transformers, electric motors, generators, compressors, pumps, drive systems, converters, or frequency inverters.APS4EM replaces individually developed planning tools and isolated solutions built up over many years with an integrated, scalable planning architecture – delivering measurable improvements in transparency, stability, and efficiency.

Transformator mit leuchtenden, gebogenen Leitungen auf dunklem Hintergrund

Hand in Hemdärmel hält Stift vor transparentem Bildschirm mit Gantt-Diagramm und Wochenübersicht

Success Story: Production planning in electrical engineering

Siemens Energy – Transformers Weiz successfully implemented the production planning tool Opcenter APS together with MCP and tailored it to the specific requirements of the electrical engineering industry.Result:

transparent and integrated production planning
Partially automated planning in winding production
optimized planning processes in insulation material production

The planning reliability gained and the time saved enable the plant to allocate resources more effectively, manage production processes in a stable manner, and consistently drive the further development of planning.

Where production planning was previously highly manual and department‑specific, Opcenter APS now generates a consistent, executable production plan that takes constraints, capacities, and dependencies into account – ensuring reliable control of complex manufacturing processes at the Weiz plant.

Full success story

Back to Opcenter APS

Your next step toward stable and economically optimized electrical engineering manufacturing

In a structured potential discussion, we analyze your rough‑cut and detailed planning processes – from multi‑level bills of materials and batch processes to the use of critical production resources.
You will receive a well‑founded assessment of realistic potential in terms of lead time, on‑time delivery performance, setup optimization, workforce deployment, and working capital – including an evaluation of project effort and implementation structure.

Schedule a potential assessment

Production planning in the electrical engineering industry – precisely controlling complex manufacturing