The Schwabmünchen plant of ams-OSRAM is a key production site in the semiconductor and optoelectronics industry.
In a highly complex manufacturing environment involving metal processing, machine scheduling, workforce deployment, and material planning, the existing planning method was inefficient and resource-intensive.

With the implementation of the DeepSynergy.AI Production Planning solution, ams-OSRAM achieved significant efficiency gains through optimized resource utilization (multi-machine operation – max. machines per employee).
The result: + 30 % machine output.

Challenge

Production planning at ams-OSRAM was a daily challenge due to high complexity. Key issues included:

• High manual planning effort:
  Daily adjustments were necessary to account for shift models, machine availability, and material inventories.

• Inefficient resource utilization:
  Machine capacities were not optimally used due to staff shortages and unused resources.

• Lack of flexibility in staff and machine assignment:
  Targeted multi-machine assignments per employee were complex to plan, limiting efficiency.

• Unforeseen events caused delays:
  Sick leave or short-term material availability issues were difficult to manually compensate.

Solution: Production Planning with DeepSynergy.AI

With the implementation of DeepSynergy.AI Production Planning, ams-OSRAM was able to fully automate and optimize its entire production planning.

• Automated machine assignment:
  Maximum utilization through intelligent capacity planning

• Detailed and sequence planning:
  Optimization of production sequences to reduce setup times

• Personnel deployment planning:
  Consideration of availability, qualifications, and multi-machine operation

• Material planning with real-time data:
  Inventory levels and delivery dates are automatically included
  
  

Key Success Factors

1. Maximum utilization of highly optimized multi-machine operation

• The optimization focused on relieving employees and preferentially using automated machines wherever technically feasible

• Through intelligent task distribution, multi-machine operation was optimized:
  One employee can operate multiple machines simultaneously

• This was made possible by integrating not only machine and personnel capacities but also their specific multi-machine capabilities into the planning

• Based on experience from similarly complex production environments, it is clear:
  Manual planning cannot fully exploit this potential – this is where the strength of DeepSynergy.AI Production Planning becomes evident

2. Improved On-Time Delivery Performance

• The optimized production plan ensures efficient processing of backlogged orders and guarantees that new orders are scheduled in a way that delivery deadlines can be reliably met.

• KPIs confirm that the DeepSynergy.AI solution enables significantly higher planning accuracy than manual processes.

3. Greater Flexibility in Workforce Deployment

• The dynamic planning system allows for targeted reallocation of employees from shifts or to other departmentswithout compromising production performance.

• This creates additional flexibility for strategic activities, training, or other value-adding processes.

4. Relief for Planners – Especially in Case of Irregularities

• Manual production planning is almost completely replaced, allowing the planning team to focus on higher-level strategic tasks.

• Even in unforeseen situations, the system shows its full strength:

  • If an employee calls in sick in the morning, the system not only reschedules but determines a new optimal plan that best utilizes available resources.

  • If a customer requests urgent priority for certain orders, the system automatically identifies the best possible solution without compromising the rest of the production schedule.

  • Changes in raw material availability are considered in real time, so production plans are dynamically and automatically adjusted.

Our optimized production plans already show how the use of our AI-based planning enables:

• Reduction of backlogs,

• Optimal utilization of machines and staff,

• And improved on-time delivery performance – even in highly dynamic production environments with many variables.
  
  

Outlook

Following the successful implementation of AI-based production planning, ams-OSRAM is planning to equip additional sites with this technology.
The goal is to establish a scalable, automated production planning and control system that not only reduces costs but also supports the company’s sustainability objectives.

With DeepSynergy.AI, ams-OSRAM was able to overcome the challenges of production planning in a highly complex environment and take a decisive step toward the Smart Factory.