Complex projects, individual customer requirements and numerous interdependent production steps make reliable production planning essential in mechanical engineering. At KARL HUGO, we are therefore continuously working to improve our internal processes. The introduction of the FELIOS planning software is another step towards digitalisation, laying the foundations for more efficient, flexible and transparent production planning.
Bringing multiple production steps together into one coordinated plan
From initial component machining to final assembly, numerous production steps, machines and employees must be carefully coordinated. Material availability, delivery deadlines and last-minute changes must also be considered in day-to-day operations. This is a complex task that requires considerable experience and an overview of the entire production process.This is where FELIOS comes in. Developed by INFORM, a company based in Aachen, Germany, the software automatically coordinates and schedules individual production steps based on available capacity. It considers factors such as machine utilisation, material availability and delivery deadlines.
If circumstances change, for instance due to an urgent customer order or a machine breakdown, FELIOS calculates the impact on ongoing production and suggests suitable adjustments. With regularly updated planning information, our employees will have a reliable basis for making decisions in their daily work.
Digitalisation is a team effort!
Implementing software such as FELIOS involves much more than just installing a new programme. For over a year, our team has been preparing data, developing interfaces, and adapting existing processes to the new system.It is particularly important to us to involve our employees throughout this process. Since September, the first team members have been testing work lists generated by FELIOS directly on the shop floor. Their experiences and feedback help us to continuously refine our planning processes. At the same time, we have been providing regular training sessions for our office staff and workshop supervisors to familiarise them with the software.
“We knew from the outset that a transition like this would take time. It’s not just about adapting our data and processes; it’s also about involving our employees right from the beginning. That’s why we’re introducing FELIOS step by step,” explains Noah Reusch.
Our aim is not to replace our employees’ expertise with software, but to provide them with practical support in their daily work. By taking over time-consuming planning tasks and centralising information, FELIOS will ultimately free up more time for activities in which our team's expertise really counts.
Greater planning reliability for our customers
Our customers will also benefit from more efficient production planning. With FELIOS, we will be able to assess project timelines more accurately at the quotation stage by taking our available capacity into account. Simulations will help us to evaluate urgent enquiries more effectively while keeping track of their potential impact on existing orders.The software will enable us to monitor production schedules more precisely and identify potential bottlenecks early on. This will provide greater planning reliability and help us to consistently meet our delivery commitments.
“When it comes to complex projects in particular, it’s important that we can provide our customers with reliable information as early as possible. FELIOS helps us assess our capacity more accurately and maintain a clear overview, even when plans change at short notice,” explains David Scholzen.
We will also be able to generate production schedules directly from the system for customers who require detailed information on their project’s progress. These schedules will show the individual stages of the manufacturing process. This will simplify communication and enable us to provide faster, more accurate updates.
Well prepared for the future
We are introducing FELIOS deliberately in stages. The software is currently in its first practical testing phase. Over the coming months, more employees will gradually become involved before the system is scheduled to run alongside our existing planning solution from early 2027.Through this project, we are investing in more than just new software; we are also investing in the continued development of our working processes. We are combining modern technology with our employees’ expertise and commitment to continuous improvement.
This will enable us to continue providing what our customers rely on: tailored solutions, high-quality products and dependable partnerships.
