Discover how companies across all industries use DeepSynergy.AI to automate, optimize, and achieve maximum efficiency in their planning processes.
AUTOMATED, HIGHLY OPTIMIZED MACHINE AND SEQUENCE PLANNING
MORE PRODUCTIVE WORKING TIME
REDUCTION IN PLANNING EFFORT
DESPITE FLUCTUATING PRODUCTION CONDITIONS
Rosenberger Hochfrequenztechnik is one of the leading manufacturers of high-frequency, fiber optic, and high-voltage connection solutions. In CNC manufacturing of electronic components, daily challenges arise from a high variety of orders, complex production workflows, and numerous planning dependencies.
Rosenberger Hochfrequenztechnik and DeepSynergy.AI rely together on innovative production planning. The key to success? A strategy tailored to their production lines for optimizing production planning – machine allocation and sequencing. In CNC manufacturing of electronic components.
With the implementation of the DeepSynergy.AI Production Planning solution, Rosenberger was able to automate production planning, increase efficiency, and sustainably improve planning quality.
Production at Rosenberger is subject to enormous complexity requirements, especially in CNC processing. The main challenges were:
High variability and dependencies
34 CNC machines with different functions and technological constraints
30 new orders daily – each part with individual requirements
More than 30 variables, conditions, and dependencies that need to be considered
Variable setup times depending on material and machine
Limited setup teams that can only perform a certain number of changeovers simultaneously
Extremely high manual planning effort
Despite a modern planning tool, many aspects of production planning could only be implemented manually
The variety of machines, materials, and setup times made automated planning previously impossible
The goal was meeting all delivery deadlines while minimizing setup and lead times
The solution had to stabilize planning quality and optimize it in the long term
After a comprehensive process and data analysis, the findings were integrated into the DeepSynergy.AI engine within a few weeks.
Customized, AI-based production planning
All variables, conditions (e.g. no setup changes during night shift), and dependencies were fully considered
Without simplifications, the ideal production process was calculated for every situation
Multi-Objective Flexible Job Shop Scheduling (MO-FJSP)
The solution considers all boundary conditions and determines the ideal production plan
Automated decisions on optimal machine and personnel assignment
Maximization of resource utilization (personnel, machine, material)
Minimization of setup times while ensuring maximum adherence to delivery dates
The planning strategy optimizes the sequence of orders, maximizing machine uptime and avoiding unnecessary downtimes
Consistently high planning quality, independent of individual planning decisions
AI-based optimization replaces error-prone manual planning
Every production plan is based on a holistic, data-driven assessment of manufacturing processes
Planners are relieved of recurring, time-consuming planning tasks
Fully automated generation of planning proposals that can be adopted or adjusted immediately
The solution dynamically adapts planning to new conditions (e.g. short-term changes in material availability or machine failures)
Automated re-optimization in case of unexpected events ensures that production targets are still met
With the successful implementation of DeepSynergy.AI Production Planning, Rosenberger has taken a decisive step toward becoming a “Top 3” manufacturer of high-speed connection technology for target markets such as Communication, Automotive, Test & Measurement, and Medical & Industrial sectors. The automation of production planning will be further expanded to establish a scalable, AI-based production planning and control system in the long term.
AI-OPTIMIZED MACHINE AND EMPLOYEE ASSIGNMENT
TO IMMEDIATELY REACT TO UNPLANNED EVENTS
REDUCTION IN PLANNING EFFORT
DESPITE FLUCTUATING PRODUCTION CONDITIONS
Spinner GmbH, a leading manufacturer in CNC machining, faced one of the biggest challenges of modern production planning: Maximum efficiency despite high complexity and variable conditions. In turning production, the goal was to optimally utilize machine and personnel capacities, minimize setup times, and at the same time ensure the highest schedule reliability.
Through the implementation of the DeepSynergy.AI Production Planning solution, production planning was fully automated and optimized – delivering significant efficiency gains for machines and personnel.
Production at Spinner GmbH was marked by complex dependencies that made planning extremely difficult:
High variability and dependencies
More than 30 different process variables, including variable setup times, machine assignments, material changes, and personnel deployment
Employee qualifications had to be considered, as not every CNC operator was allowed to perform setup
Multi-machine operation had to be optimized to make better use of personnel
Planning conflicts between setup time minimization and schedule reliability
The objective was to meet all delivery deadlines while simultaneously minimizing setup times
Especially challenging: avoiding night shift setups (a social planning goal), while still maximizing machine utilization
High manual planning effort
Despite modern planning tools, planning could only be optimized manually
Fluctuating planning quality led to inefficiencies
Long-term optimizations were lacking, as short-term solutions were prioritized
After a comprehensive data and process analysis, the DeepSynergy.AI engine was integrated into the production system of Spinner GmbH within a few weeks.
Fully automated production planning
Optimal allocation of machines and personnel for each job
Compliance with all qualification requirements in setup and production planning
AI-powered multi-machine operation, enabling one employee to operate up to three machines simultaneously
Optimized setup time planning
Minimization of setup times as the primary goal, considering all process conditions
Preferred setup during early/late shifts to avoid night shifts
Dynamic adaptation to material changes to reduce waiting times
Real-time optimization in case of changes
If an employee is absent or orders are rescheduled, DeepSynergy.AI Production Planning immediately calculates a new optimal plan
Machine downtimes are minimized, as planning flexibly responds to unplanned events
AI-optimized sequence planning reduces unnecessary changeovers
Material and tool changes are strategically planned to minimize downtimes
Preferred setup during early & late shifts to maximize efficiency and machine runtime
Employees operate multiple machines simultaneously to increase productivity
Automatic adjustment of machine workloads to capacity and qualifications
Planning considers parallel activities (e.g. setup + production) to avoid time losses
Real-time optimization when staffing or machine capacity changes
Automatic adaptation of planning to order fluctuations
High delivery reliability despite fluctuating production conditions
Up to 90% less manual planning work, as AI automatically calculates the optimal solution
Consistently high planning quality, regardless of individual planning decisions
Fully automated creation of planning proposals, which can be directly adopted or adjusted
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