How do you reduce quality costs through better production planning?
In many printing companies, insufficient planning leads to a lack of transparency regarding actual capacity utilization and lead times.Orders are accepted even when capacity is insufficient. Bottlenecks only become visible in the short‑term horizon. Operational pressure increases, processes accelerate uncontrollably – and quality suffers.Typical consequences:
- Rework due to quality deviations
- late deliveries
- unplanned material reallocations
- increasing quality and margin losses
These inefficient processes can be eliminated with integrated production planning
MCP supports folding carton printing companies in transforming evolved planning structures into a transparent, system‑supported end‑to‑end process.Existing expertise is retained – but enhanced through algorithm‑based planning.The result:
- Reliable capacity forecasts
- less operational pressure
- clearly structured decision‑making processes
- lower personal workload for planners
- higher planning stability in replacement situations
high personnel effort to compensate for lack of planning reliability
Manual coordination of external subcontractors
Multiple Excel‑based plans without a consistent data foundation
Time‑consuming scheduling meetings without a reliable forecast
Continuous phone‑based coordination between printing, finishing, and dispatching
Measurable impact in folding carton printing companies
Through integrated, capacity‑constrained production planning, economically relevant improvements can be achieved:
20%
higher productivity
30%
lower quality costs
30%
reduced inventory levels
30%
fewer delivery delays
100%
significantly higher planning reliability
Control your day‑to‑day operations in a structured way with integrated production planning
Opcenter APS
- Hygiene regulations
- Sheet formats and material dependencies
- Approvals and print sequences
- Setup families (color, format, material)
- Machine‑dependent output rates
- Workforce availability and qualifications
- Scheduling of external subcontractors
Manual optimization via drag & drop remains possible – in a targeted and controlled way.Through full constraint modeling, a consistent, capacity‑secured overall plan is created – without parallel Excel structures.
What changes for the planner?
- Proactively secure bottlenecks (Drum‑Buffer‑Rope principle)
- Planabweichungen analysieren und KVP-Maßnahmen ableiten
- Prepare decision‑making meetings based on data and facts
- Professionalize customer service through transparent delivery reports
Avoid waiting times at bottlenecks by proactively reviewing upstream processes and adjusting buffers in front of the bottleneck (Drum‑Buffer‑Rope principle).
Analyze plan deviations and derive continuous improvement measures, such as adjusting setup matrices, output rates, etc.
Analyze plan deviations and derive continuous improvement measures, such as adjusting setup matrices, output rates, etc.
Expand customer service, e.g. by automating reports on quantities and delivery dates for key customers
Control flexibility economically – instead of reacting hectically
Late layout approvals or short‑term quantity changes do not have to lead to chaos.With weighted objective planning (on‑time delivery vs. setup optimization), a balanced schedule is created.What‑if scenarios enable:
- Immediate simulation of quantity changes
- Transparent impact on other orders
- Reliable date confirmation during customer discussions
- Clear buffer transparency across all process steps
You remain in full control of lead time, quality, and margins at all times.
Your next step toward stable and economically efficient folding carton production
In a structured potential discussion, we analyze your printing, finishing, and subcontracting processes and identify concrete economic levers – from reducing quality costs to increasing productivity.