Order SLA Protection & Overtime Minimization During Demand Spikes
A commercial HVAC equipment manufacturer producing custom rooftop air handling units with high seasonal demand surges during pre-summer months.
Run on Niyojan · Production Planning & Scheduling
The challenge
A 45% seasonal surge in customer orders threatened contract delivery SLAs, risking heavy liquidated damage penalties.
Plant managers authorized uncoordinated weekend overtime across all departments, driving labor costs up by 35% without resolving specific assembly bottlenecks.
Planners could not determine which specific departments actually required overtime to protect delivery SLAs.
How Niyojan solves it
Demand Surge Schedule Simulation
Niyojan models incoming order volumes against finite plant capacity, identifying exact delivery SLA breach risks.
Targeted Bottleneck Overtime Optimization
Calculates the exact minimal overtime hours required exclusively at bottleneck work centers (e.g., coil brazing) to preserve 100% of order SLAs.
Non-Bottleneck Shift Smoothing
Schedules non-bottleneck departments (e.g., sheet metal fabrication) on standard shifts, eliminating unnecessary overtime spend.
Dynamic Customer Priority Rules
Sequences orders by contract penalty severity and customer SLA windows automatically.
Labor Budget vs SLA Trade-Off Analytics
Provides plant directors with clear cost-benefit dashboards for alternative overtime proposals.
The outcome
- on-time delivery maintained across pre-summer demand spike
- 0%on-time delivery maintained across pre-summer demand spike
- reduction in overtime labor spend by restricting overtime
- 0%reduction in overtime labor spend by restricting overtime
100% on-time delivery maintained across pre-summer demand spike season with zero SLA penalty fines.
62% reduction in overtime labor spend by restricting overtime exclusively to identified bottleneck workstations.
Preserved project gross margins while absorbing a 45% volume surge.
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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