AI Production Planning Enables $1.9M Annual Revenue Growth at Bednar FMT
Transition to Line-Based Manufacturing Made Manual Planning Unsustainable at Scale
Bednar FMT transitioned from cell-based to line-based manufacturing during COVID-19, creating significant planning complexity. The company faced underutilised production lines, inaccurate labour planning causing missed deadlines, and supply chain delays. Manual planning could no longer handle the increased operational demands as the business scaled.
AI Evaluates Millions of Production Scenarios in Seconds, Generating the Optimal Plan
Blindspot developed a production planning application using the Adastra OptiSuite optimization platform. The system evaluates millions of production scenarios within seconds, generating optimal plans that account for line capacities, delivery deadlines, shifts, work sequences, and technological constraints.
One Planner Replaced Three, Planning Cut to Minutes, and $1.9M in Additional Demand Unlocked
The system unlocked the potential to meet €1.75 million in additional annual demand. Planning was reduced from hours to minutes, and one planner replaced three workers. The process became faster, standardised, and more flexible, with real-time automated planning and scenario testing. Material in production areas was reduced, moving the company toward just-in-time logistics.
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Automated Inspector Scheduling Reduces TÜV SÜD Planning Team by 33%
Managing inspector dispatch across multiple China hubs via Excel was no longer viable at scale. Blindspot replaced the fragmented process with a centralised scheduling platform, cutting the scheduling team from six to four and handling peak seasons without bottlenecks.
GZ Media Achieves 6-Month ROI with AI-Optimized Label Printing
The world's largest vinyl record producer replaced error-prone Excel-based print bundling with an AI system that plans automatically overnight, reducing planning from hours to minutes and achieving full ROI within six months.
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