Assan Aluminium increases delivery performance and production output with Quintiq

August 18, 2008 | 's-Hertogenbosch, Netherlands
Turkey's largest producer of cold rolled aluminum and foil, Assan Aluminium, achieved significant improvements with the implementation of the Quintiq Scheduler and Quintiq Company Planner.

Assan implemented the Quintiq APS solution at their plant in Tuzla, near Istanbul, to schedule seven continuous strip casters, cold mills, foil mills and downstream activities. The program was introduced in the Tuzla plant in three phases. The first phase was to plan all incoming raw materials and coil production for coil, sheet and foil production and create all the job orders using the Quintiq Scheduler. The second phase was to schedule these job orders and optimize operations, again, using the Scheduler module. The third phase uses the Quintiq Company Planner to generate due dates and create production plans 1-3 months ahead.

"Investment in further modules is likely," says Mrs Gülbin Kulak, Resources Planning Director, "with Macro Planner to be introduced in the future in order to cover budgeting and plans 5 to 10 years ahead. Previous planning systems were in-house developments and required considerable knowledge input by the user. The models used in Quintiq's APS suite capture this knowledge and retain it for the future, reducing the reliance on a few key personnel who may be absent at a critical time."

Commercial systems other than Quintiq's were considered, but the Quintiq APS was selected as the most appropriate and flexible for their needs. Alpay Eksi, Resources and Production Planning Manager states: "Since implementing the Quintiq Company Planner and Scheduler modules and using the APS approach, output has increased by 10% without the need for any additional equipment, and delivery performance improved by 20%."

Further, yields have improved significantly as no additional raw material inputs have been required to increase output. Current output capacity at Tuzla is about 130kt/y. The software has enabled the planning horizon to change from tons to time with output based on Key Performance Indicators (KPIs).

Assan recently acquired a second plant in Dilovasi, about 25km from Tuzla, and plans to introduce the Quintiq APS there. Total output from both plants is planned to grow to 240 kt/y of coil, sheet and foil by 2010. This will require the number of continuous casters at Dilovasi to be increased from 5 to 10 and at Tuzla from 7 to 8. Maximum width in Tuzla is 2400mm.

About Assan
Assan has been serving the domestic and international markets since 1988 with superior quality of flat rolled products mainly for distribution, construction, automotive, consumer durables sectors and other technical applications. Assan also produces foil products for flexible packaging, household foil, container foil and other industrial applications. Utilizing the world's widest thin gauge speed caster lines, Assan is the largest and the fastest growing aluminium producer in Turkey with an annual continuous casting capacity of 200,000 tons.

About Quintiq
Quintiq provides advanced planning, scheduling and supply chain optimization solutions. The fast-growing Dutch company, established in 1997, offers software for planning and optimizing complex business processes throughout the enterprise. The company's headquarters is located in the Netherlands and it has subsidiaries in Germany, UK, Finland, Malaysia, China, Australia, and the USA.