Do we need to replace our ERP or MES?

No. The engine sits on top of your existing ERP and MES through standard connectors, reading orders and constraints and writing back optimized schedules.

How long before we see throughput gains?

Most clients see measurable throughput and changeover improvements within 3-6 months, once the model is trained on a few cycles of real production data.

Can it plan across multiple plants?

Yes. We model multi-site networks and balance load across plants based on capacity, cost, and proximity to demand.

What data do you need to get started?

Your routings, machine and labor constraints, changeover rules, and a history of past orders. We work with whatever you have and fill the gaps during the audit phase.

How does it balance cost against speed?

You set the objective. We weight cost, speed, on-time delivery, and energy use to match your priorities, and you can re-tune the balance at any time.

Manufacturing Analytics

Intelligent Production Planning & Optimization Built for Throughput

Maximizing throughput, minimizing setup changeover, and reducing waste with AI-driven production scheduling and dynamic resource allocation on the factory floor.

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The Perfect Schedule

Balancing labor, machines, tooling, and material flow is a massive combinatorial challenge. Standard scheduling tools leave lines idle during changeovers and fail to absorb shift disruptions. We deploy constraint-based optimization engines that compute the most efficient production path in real time, then sync those schedules directly with demand forecasts, so the factory floor runs at peak throughput while eliminating the costly overproduction that ties up cash and space.

The Old Way

Manual Planning

The Intelegencia Way

AI Optimization

Sub-optimal Schedules

Mathematical Peak Efficiency

High Changeover Waste

Minimized Idle Time

Labor Under-utilization

Dynamic Resource Leveling

Fragile Bottlenecks

Robust Throughput

Reactive Re-planning

Real-Time Rescheduling

Constraint-Based Scheduling

Our scheduling engines ingest millions of operational variables (labor shifts, machine capacities, and tooling setups) to solve complex routing problems. The solver maps the optimal sequence of jobs, automatically clustering similar runs to reduce changeover downtime. This ensures you hit every delivery commitment at the lowest possible production cost.

Advanced Heuristic Solvers

Labor-Shift Optimization

Changeover Reduction Logic

Material-Flow Balancing

Energy-Cost Aware Scheduling

Demand-Synced Production

A perfect schedule for the wrong demand still loses money. We tie your production plan directly to live demand forecasts, so volume, mix, and timing track what the market is actually about to buy. When the forecast shifts, the plan shifts with it, protecting you from both overproduction and missed orders. We keep the floor in lockstep with demand.

Forecast-driven master scheduling

Product-mix optimization

Build-to-demand sequencing

Safety-stock right-sizing

Surge and dip absorption

Rescheduling the Moment Things Change

Plans break the second a machine goes down or a rush order lands. Our engine re-optimizes the rest of the shift in seconds, reshuffling jobs, labor, and materials to protect your delivery dates instead of blowing them. Supervisors get a clear, ranked set of moves rather than a frozen spreadsheet. We turn disruption into a routine adjustment.

Real-time re-optimization

Rush-order insertion logic

Breakdown impact containment

Dynamic labor reallocation

Priority-aware job sequencing

The Throughput Stack

Planning Units

Constraint-based scheduling, demand-synced production, real-time rescheduling, and digital twin simulation converging to maximize throughput, minimize changeover, and protect delivery dates.

Bottleneck Analysis

Identifying and resolving the 'Slow Point' in your line.

Resource Leveling

Ensuring labor and machines are used at peak efficiency.

What-If Simulator

Testing new shifts or machines before implementing them.

KPI Dashboard

Real-time OEE (Overall Equipment Effectiveness) tracking.

Test Before You Commit

Buying a machine or adding a shift is a big bet. We build a digital twin of your line so you can simulate those changes against real constraints and see the throughput, cost, and bottleneck impact before you spend a dollar. Compare scenarios side by side and walk into the decision with the numbers already proven.

Digital-twin line modeling

Capacity what-if scenarios

Bottleneck shift analysis

Capex impact simulation

Side-by-side scenario scoring

The Road to Efficiency

Our Planning Flow

Five steps that move you from manual scheduling to AI-driven optimization, covering constraint mapping, model training, baseline validation, live ERP integration, and continuous performance refinement.

Process Audit

Mapping every step and constraint in your line.

Model Build

Coding your specific manufacturing constraints.

Baseline Test

Comparing AI schedules to your historical best.

Live Integration

Connecting the engine to your ERP and shop floor.

Continuous Loop

Refining the model based on real-world throughput.

Measured Performance. Proven Growth.

Throughput

Changeover Time

Machine Utilization

On-Time Delivery

Frequently Asked Questions
About Intelligent Production Planning & Optimization

Here you will find answers to questions we get asked the most about our offerings.

The AI 'Re-optimizes' in real-time, instantly adjusting the rest of the day's schedule to minimize the impact of the stoppage.