Business Case Study: Enhancing Production Scheduling Efficiency for a Leading Electric Motor Manufacturer

Winning Solutions, Inc. (WSI) partnered with a prominent electric motor manufacturing company with facilities in Bozeman, Montana, and Boston, Massachusetts to overhaul and enhance their existing Production Scheduling Database Template. This comprehensive project, conducted between September and October 2023, focused on improving scheduling accuracy, managing multi-location operations, and optimizing the overall efficiency of production processes. By leveraging the power of Microsoft Access and Microsoft SQL Server, WSI delivered a powerful, scalable solution tailored to the client’s evolving manufacturing needs.

Key Challenges

The client faced several operational challenges including:

• Coordinating machine schedules across two geographically distinct facilities.
• Managing different machine types (Mills, Lathes, Outsource operations).
• Preventing scheduling conflicts and overlaps across interdependent machines.
• Improving user interfaces for intuitive operation and accurate reporting.
• Ensuring the database was multi-user capable with real-time data consistency.

Project Goals and Strategic Objectives

• Enhance scheduling accuracy and consistency across all locations.
• Enable conflict-free machine scheduling with robust validation.
• Facilitate reporting through export features and calendar-based views.
• Restructure the database into a Front-End/Back-End (FE/BE) model for multi-user access.
• Customize user interfaces to match the client's production terminology and workflows.

Phase 1: Foundational Enhancements

WSI implemented foundational improvements in the first phase, including:

• Location management capabilities for toggling between facilities.
• Integration of various machine types with dynamic selection.
• Replacement of outdated fields with more relevant scheduling data points.
• Addition of new data inputs such as Part Number for detailed tracking.

These changes laid the groundwork for a more flexible and robust scheduling system, allowing the client to effectively manage complex production workflows.

Phase 2: Advanced Features and User-Centric Enhancements

Following successful deployment, WSI worked closely with the client to incorporate advanced refinements:

• Brand integration with custom logos and UI branding elements.
• Redesigned calendar views to display Quantity, Part Number, and status (e.g., Completed).
• Intelligent conflict detection and resolution with dynamic rescheduling logic.
• Customized forms for adding and updating schedules, ensuring seamless user experience.
• Export-to-Excel functions for streamlined reporting, while removing outdated Outlook export features.
• Introduction of a "Completed" checkbox and visual indicators in calendar views.

Solution Implementation

The solution utilized a 64-bit Microsoft Access front-end with a Microsoft SQL Server backend hosted on the client’s peer-to-peer Windows network. This architecture enabled multi-user access, streamlined data input, and real-time updates with minimal disruptions. WSI restructured the database logic to validate schedules during both creation and modification, automatically updating downstream entries as necessary.

Measured Results and Business Impact

• Enhanced Scheduling Efficiency: Dual-location scheduling became streamlined and highly reliable.
• Improved User Controls: Staff could dynamically modify part types and view relevant data easily.
• Multi-User Access: FE/BE separation enabled simultaneous use without conflict.
• Streamlined Reporting: Enhanced export functions empowered quick data analysis and decision-making.
• Greater Data Accuracy: Automated validations eliminated scheduling conflicts and improved production flow.

Lessons Learned and Future Planning

• Customization Flexibility: The project demonstrated the value of adaptable systems that respond to shifting business needs.
• User Testing: Active client involvement ensured features matched operational expectations.
• Iterative Development: A phased approach allowed refinement and successful incremental delivery.

Next Steps and Considerations

• Integration with ERP systems for centralized data management.
• Implementation of advanced analytics dashboards for real-time insights.
• Potential cloud migration for enhanced scalability and remote accessibility.

WSI’s partnership with the client resulted in a highly customized, scalable, and efficient production scheduling solution. The collaboration underscored the power of targeted database development and iterative project execution in transforming manufacturing workflows. For expert support in database customization and business process optimization, Contact Us today.