- high number of parallel orders and a fluctuating product mix
- Setup optimization within and across SMD lines
- late detection of missing parts and material shortages
- conflict between on‑time delivery performance and setup minimization
- Splitting decisions in the event of bottlenecks
- Transparency on WIP and actual lead times
Your challenges in production planning in electronics manufacturing:
A high number of parallel orders, complex material dependencies, and multiple lines with a fluctuating product mix significantly increase planning dynamics.
Machine capacities, setup families, and material availability create high complexity in delivery date validation and sequencing.
Missing parts often only become visible in the short‑term horizon. This leads to rescheduling, additional setup changes, and delivery risks.
Fluctuating demand across highly automated lines and manual workstations requires a balanced approach between flexibility and economic efficiency.
Siemens Numerical Control develops and manufactures numerical control systems for international markets. The challenges faced by SNC include a high level of product variety and complexity, as well as rapidly growing production demand. Customers expect shorter lead times, while SNC has high levels of inventory in the workshop. Find out how these challenges are addressed with Opcenter APS (formerly SIMATIC IT Preactor APS) in the video.
Planning architecture for SMD and THT production
Rough‑cut planning
- Long‑term capacity planning for lines, workforce, and additional shifts
- Automatic planning for high order volumes and varying product mixes
- Berücksichtigung von Rüstfamilien als Basis für Rüstoptimierung
- Automatic order splitting in the event of bottlenecks
- Selection of alternative routing plans based on defined criteria
- Load leveling of line utilization
- Scenarios for delivery date commitments (“what‑if”)
- Reduction of WIP and material inventories
- Cascaded planning across multiple production stages
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- Capacity‑constrained sequencing with realistic start and end times
- Flexible weighting of objective criteria (on‑time delivery, setup minimization, WIP reduction)
- Critical ratio logic for highly variable process times
- Integration of SMT optimization systems (e.g., SiCluster, VALOR)
- Workstation assignment taking qualifications and utilization into account
- Machine‑dependent process time calculation per batch size
- Continuous re‑optimization in the event of disruptions
- Precise scheduling of short‑term high‑priority orders
- Interface to automated warehouse systems
Your benefits from an integrated production planning solution for electronics manufacturing
Realistic, parameter‑driven scheduling
Fully modeled workstations and lines for stable, realistic planning.
Reduced planning effort
Algorithmically optimized planning with full intervention capability for planners.
Higher line productivity
Early detection of bottlenecks and scenarios for capacity adjustments or splitting.
Full modeling of all constraints
Machines, setup families, material dates, personnel, qualifications, and maintenance in a single system.
Reduced WIP inventories
Pull‑oriented production based on the current detailed schedule.
More stable operations on the shop floor
Longer planning horizon, fewer short‑term changes, greater transparency.
Global brands trust Sunstice
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“With Opcenter APS, we have been able to significantly improve our on‑time delivery performance and profitability. Our production planning is now a true competitive advantage.”
SUMIDA Lehesten GmbH is a global manufacturer of high‑quality inductive components and modules. SUMIDA products are used in consumer goods, household appliances, automotive electronics, renewable energy, industrial electronics, and medical devices.Together with MCP, SUMIDA optimized its production planning using constraint‑based APS algorithms and integrated setup optimization.Result:
- On‑time delivery performance increased from 62% to 98%
- Lead time reduced by 35%
- significantly improved planning transparency within the plant
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TDK Electronics, a subsidiary of the TDK Group, is a leading global manufacturer of electronic components and systems, with around 20 development and production sites in Asia, Europe, North and South America. The company focuses on technologically demanding growth markets in automotive, industrial and consumer electronics, as well as information and telecommunications technology.With an existing detailed planning setup based on SAP, Excel, and isolated solutions, increasing product variety and multidimensional constraints could no longer be managed efficiently.Opcenter APS enables integrated, algorithmic detailed scheduling with automated consideration of constraints and significantly reduces manual intervention in the short‑term planning horizon.Read our success story on the design of an electronics production planning solution with Opcenter APS at TDK Electronics.
Your next step toward stable and efficient electronics manufacturing
In a structured potential discussion, we analyze your SMD, THT, and assembly processes holistically and identify concrete economic levers – from setup optimization and WIP reduction to the sustainable improvement of on‑time delivery performance.
You will receive a well‑founded assessment of productivity, inventory, and service level potential, as well as implementation effort and project structure.