Global 60+ Plant Capacity Balancing & Workload Re- Allocation
A multinational industrial equipment manufacturer operating 60+ production facilities across 4 continents, producing custom hydraulic pumps, valves, and heavy gearboxes.
Run on Niyojan · Production Planning & Scheduling
The challenge
Primary manufacturing facilities in North America operated at 95% capacity overload while secondary plants in South America sat underutilized at 60% capacity.
Planners managed facility schedules in isolated spreadsheet silos, making cross-factory workload re-allocation slow and complex.
Overloaded plants incurred massive unplanned overtime costs while underutilized plants suffered idle labor overhead.
How Niyojan solves it
Enterprise 60+ Plant Command Cockpit
Niyojan unifies active order books, machine utilization rates, labor availability, and shipping logistics across all 60+ facilities into one live dashboard.
Automated Multi-Plant Order Allocation
Evaluates global machine capabilities, tooling availability, customer delivery windows, and freight costs to calculate optimal order placement.
Dynamic Capacity Balancing
Automatically re-allocates standard product runs from overloaded North American plants to open capacity bays in South America.
Global Constraint Identification
Flags multi-plant bottlenecks (e.g., global shortages of specific heat- treatment furnace hours) before schedule commitments are released.
Master Production Schedule Dispatch
Publishes synchronized master schedules directly to local plant ERP execution systems.
The outcome
- overall increase in enterprise fleet capacity utilization
- 0%overall increase in enterprise fleet capacity utilization
- reduction in unplanned overtime costs by balancing workload
- 0%reduction in unplanned overtime costs by balancing workload
18% overall increase in enterprise fleet capacity utilization across 60+ manufacturing plants.
75% reduction in unplanned overtime costs by balancing workload evenly across global facilities.
Accelerated global master planning cycle time from 10 days to 2 hours.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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