200 open orders.
Every morning the same question:
What do we do first?
At high variance, sequence determines delivery reliability. RheoNet shows which order will blow the plan — and why — before it is too late.
Typical challenges in mechanical engineering
Six problems every production manager in high-mix manufacturing knows.
Delivery dates slip — without warning
The root cause is rarely where you expect it. Often it is a single purchased part, a machine that broke down three days earlier, or a reprioritization made two weeks ago. ERP does not show this.
Plan and reality drift apart daily
ERP knows the target state. The shop floor lives in the actual state. Between them lies a gap — bridged manually every morning by two experienced planners.
Firefighting as a permanent state
Express orders, reprioritizations, capacity crunches. The production manager plans with 3 Excel files. Every disruption costs hours of replanning, not minutes.
Variant diversity makes every order a special case
Every order has its own routing, times and resources. Planning cannot standardize — and is therefore as costly as the manufacturing itself.
WIP grows with every new order
More orders in the system means more complexity, not more throughput. Releasing too much clogs the shop floor. But releasing too little wastes capacity.
Capacity bottlenecks become visible too late
A critical workstation that becomes a bottleneck in 5 days — nobody sees this today. The reaction comes when the delay has already happened.
How RheoNet helps in mechanical engineering
Connect ERP + MES + shop-floor feedback
We connect your planning data (ERP) with shop-floor realities (MES, confirmations). No system change needed — standard exports suffice. Up and running in weeks, not months.
Plan-vs-actual comparison & drift detection in real time
See where the plan is deviating from reality — before the delay has occurred. Which order will be late? Which resource is today's bottleneck? Which will be in 3 days?
Daily prioritization recommendations
What should be released today? Where is a capacity intervention worthwhile? What can wait? Data-driven recommendations — every morning, in the context of all open orders.
Measurable results
8–15%
WIP reduction
Fewer orders in the system simultaneously. Focus on flow instead of open orders.
<6 mo.
Payback
Less rush costs, fewer overtime hours, shorter lead times. Calculated conservatively.
2–3 wks
First insights
Rapid Factory Assessment: top-5 delay drivers + quick wins — before the pilot starts.
"We had 200 open orders and every morning started with the question: what do we do first? That was no longer planning — it was intuition under pressure."
— Typical feedback from high-mix manufacturing
Does RheoNet fit your operation?
20 minutes is enough. We'll show you which orders are about to blow your plan today — and what you can do about it.
Schedule a call