Transforming production efficiency and enhancing resilience with Proficy Scheduler

KiiltoClean A/S in Assens, Denmark is specialized in workplace hygiene such as soaps, creams, hand sanitation and disinfectants. Products are delivered in product containers of many different sizes, ranging from 30 ml tubes to 1,000-liter IBCs. Core competences are mixing, filling and transporting to storage.

KiiltoClean A/S is a subsidiary of the Finnish Kiilto Group. Kiilto was founded in 1919 and currently has subsidiaries and production facilities in 9 countries, including Denmark, Norway and Sweden. Kiilto has 1,000+ employees, of which 95 work in Assens, Denmark.

In March 2014, KiiltoClean initiated the process of implementing Proficy Scheduler in their production in Denmark, with the aim of addressing several key challenges. The primary objective was to improve the efficiency of their scheduling to ensure they could meet agreed delivery dates while maintaining a high degree of flexibility and retaining the ability to make quick changes in production. Additionally, they aimed to reduce stock levels to improve cash flow and to reduce storage costs. They also wished to prepare operations to handle increased complexity and larger volumes in the future. Søren Arevad Barnkob, production planner at KiiltoClean says:

“We have succeeded beyond our wildest expectations, even expanding our product portfolio and increasing production volumes concurrently with the implementation of Proficy Scheduler. Our scheduling was carried out manually, and it was slow and cumbersome to make changes in our plan. We operate in three shifts and schedule everything from mixing to filling. We produce to order and to stock. We have improved routing between mixing and filling operations, and we save time and resources with Proficy Scheduler.”

Proficy Scheduler has become an important tool in strategic planning and purchasing at KiiltoClean, because the overview is now significantly better. Via Proficy Scheduler the company gets a full overview of the capacity. An overview that provides insights that improve decision-making in a broad range of production-related functions: from recruiting, expansion of calendars and assessment of the need for weekend shifts to deciding whether to bring in sub suppliers during peak production periods.

”We run a much more flexible production. We can adapt to changes at a much earlier stage. We can keep our stocks low and release capital. Proficy Scheduler provides a much more comprehensive overview, and it is much faster. I can do the detailed scheduling on over 1,000 production orders in a matter of 15 seconds – it is simply fantastic,” Søren explains.

It is crucial for manufacturing companies with an optimal overview over the production and especially when unforeseen events occur. In an ever-changing global landscape, manufacturing companies face a myriad of challenges, from economic downturns to unforeseen events like the COVID-19 pandemic. The ability to adapt and maintain operational continuity during such crises is crucial for long-term success.

The COVID-19 pandemic presented unprecedented challenges for businesses worldwide, including KiiltoClean. The agility and flexibility provided by Proficy Scheduler were invaluable during the pandemic and the ability to make real-time adjustments and maintain a comprehensive overview was crucial for KiiltoClean especially as they were obliged to deliver essential products to hospitals and healthcare facilities.

Søren reflects on the critical role Proficy Scheduler played during this turbulent time:

“We could not have managed it without Proficy Scheduler during the pandemic. In the beginning we had no idea what this was, however, we could sense that this was wild. Every morning, we had a meeting where our CEO went in and helped to prioritize what we were going to produce, because we were told by the Danish government that we HAD to deliver to hospitals. The good thing about Proficy Scheduler during this hectic period was that we could make new plans right away and see changes as we got new guidelines for what to produce and where to deliver. We could change everything continuously and still have the full overview. We were running around the clock and were just so busy, but we could manage all this because of Proficy Scheduler. Without a doubt Proficy Scheduler has truly been a game-changer for us. We now have an optimal overview of our production processes, which has allowed us to be more agile and responsive. Whether it's a change in customer demand or an unexpected event, we can adapt quickly and maintain our high standards of quality and service.”