Production planning in the chemical industry requires maximum control

Efficient production planning is essential in the chemical industry. Companies must take into account complex formulas, limited tank capacity, strict safety regulations, quality controls, and fluctuating customer demand on a daily basis. At the same time, it is important to make optimal use of facilities and maintain high delivery reliability.

Many chemical companies still plan their production using ERP systems or Excel. While this provides an overview, it makes it difficult to respond quickly to changes. An unexpected outage, a delayed delivery of raw materials, or a rush order can have major consequences for the entire schedule.

That is why more and more chemical companies are opting for smart production planning using artificial intelligence and a digital twin.

Why Traditional Production Planning Is Insufficient

ERP systems are excellent at tracking orders, inventory, and production data. But determining the optimal production sequence remains largely a manual process.

Planners must constantly weigh the following factors:

• available production capacity;
• tank and storage capacity;
• raw materials;
• changeover times;
• safety regulations;
• delivery arrangements;
• staffing;
• maintenance planning.

When all these factors come together, it becomes increasingly difficult to create the best schedule manually.

AI calculates the optimal production schedule

Artificial Intelligence can analyze millions of possible schedules in just a few minutes and select the one that best aligns with your organization’s objectives.

In doing so, AI takes into account, among other things:

• production capacity;
• availability of facilities;
• recipes;
• raw materials;
• delivery times;
• maintenance;
• staff scheduling;
• energy consumption;
• security restrictions.

This results in a schedule that is not only efficient but also practical to implement.

Test different scenarios using a Digital Twin

With a Digital Twin, you create a digital copy of your production environment. This allows you to simulate new schedules before actually implementing them.

For example:

• What happens if a reactor unexpectedly shuts down?
• Which schedule yields the highest production capacity?
• What are the consequences of a delayed delivery of raw materials?
• Is an additional production run cost-effective?
• How does maintenance affect delivery reliability?

By simulating scenarios in advance, decisions are better informed and production flexibility increases.

Specific Challenges in the Chemical Industry

The chemical industry faces unique planning challenges that go beyond just capacity and lead times.

Campaign Production and Setups

Many chemical companies operate in production runs where the same products or similar formulations are manufactured one after another. Choosing the right production sequence minimizes cleaning, changeovers, and downtime. AI can automatically calculate this optimal sequence.

Formulas and Raw Materials

Chemical production relies heavily on precise formulas and the availability of raw materials. When a raw material is unavailable or an alternative formulation is needed, this directly affects scheduling. Smart scheduling automatically takes these dependencies into account.

Tanks, Storage, and Logistics

It is not only production capacity that is a determining factor, but also the availability of tanks, silos, and storage locations. If a storage tank is still in use or a truck is delayed, this can affect the entire schedule. Taking these constraints into account results in a more realistic production plan.

Safety and Laws and Regulations

The chemical industry operates under strict regulations, such as REACH, ADR, and other safety regulations. In addition, internal safety procedures often apply to hazardous substances and product combinations. Effective production planning supports these requirements and helps mitigate risks.

Production Scheduling and APS for the Chemical Industry

In the chemical industry, production planning is often referred to as “production scheduling” or “Advanced Planning & Scheduling” (APS). This involves not only planning production orders, but above all determining the optimal production sequence while taking all technical and logistical constraints into account.

A modern APS system automatically takes into account, among other things:

• campaign production;
• recipes;
• tank capacity;
• changeover times;
• availability of raw materials;
• maintenance;
• security restrictions;
• delivery arrangements.

PlanWisely combines APS with artificial intelligence and a digital twin. This creates a realistic production schedule that can be continuously optimized as conditions change. Planners gain immediate insight into the impact of changes and can compare different scenarios before making decisions.

Why a Digital Twin Is Especially Valuable in the Chemical Industry

In a chemical plant, changes often affect multiple processes at the same time. A different production sequence can have implications for tank occupancy, logistics, maintenance, and deliveries.

With a Digital Twin, you can visualize these effects in advance. This way, you’ll know which schedule yields the best results without taking any risks in actual production.

The Benefits of AI-Powered Production Planning

Through smart production planning, chemical companies achieve, among other things:

• greater delivery reliability;
• more efficient use of equipment;
• less downtime;
• less changeover time;
• more efficient use of tanks and storage;
• respond more quickly to disruptions;
• less planning pressure;
• better-informed decisions.

PlanWisely: AI-powered production planning for the chemical industry

PlanWisely combines artificial intelligence with a digital twin to make production planning smarter, faster, and more reliable.

Instead of manually calculating various scenarios, PlanWisely automatically calculates the optimal schedule based on the current situation. Thanks to the Digital Twin, you can simulate changes before implementing them.

This allows you to gain better control over complex production processes, make better use of available capacity, and respond more quickly to changes in the market or in production.

Curious about how AI-powered production planning can improve your chemical production? Contact us for a demonstration and discover what a Digital Twin can do for your organization.