How did Three Sigma Technologies improve scheduling?

By implementing Skody AI APS, Three Sigma reduced scheduling time from 3-4 days to just seconds. They extended their planning horizon from 1 week to 1 year and achieved a 15% reduction in production delays.

What challenges did Three Sigma face with Excel scheduling?

Excel lacked standardized scheduling, leading to inconsistent quotes and deliverables. Newer team members couldn't produce reliable estimates, relying on tribal knowledge from senior staff, creating bottlenecks and single points of failure.

How does Skody AI APS integrate with ERP systems?

Skody AI integrates with ERP systems for real-time data accuracy, enabling dynamic communication that eliminates double entries and reduces errors in production data. It models CNC constraints like tool changeovers and machine availability.

Three Sigma Technologies Case Study

Implementation Goals

Three Sigma aimed to address critical challenges in its production process by implementing Skody AI APS, with the following objectives:

Reduce production delays by optimizing scheduling
Adapt schedules dynamically to account for machine availability, employee downtime and material delays
Streamline production planning processes for greater efficiency
Replace Excel-based scheduling with a more advanced, automated easy to use tool

The Challenge: Inefficient Excel-Based Scheduling

Three Sigma's complex production processes required sophisticated scheduling solutions. Initially, the company relied on Excel, which, while functional as a spreadsheet, fell short for advanced production planning.

The lack of a standardized scheduling approach led to inconsistent project quotes and deliverables. Newer team members struggled to produce reliable estimates, relying heavily on the intuition of senior staff. This dependence on tribal knowledge created bottlenecks, single points of failure, and inefficiencies in the scheduling workflow.

Why Scheduling Wasn't the Sole Objective

While replacing Excel was necessary, the primary goal was to meet the aerospace industry's demanding requirements and customer expectations. Beyond reducing inventory, Three Sigma needed to align production schedules with material availability.

Working with suppliers serving aerospace industry giants, the company faced frequent component delays, which disrupted production. Previously, creating a production schedule took four days, and any delay in material delivery or machine availability required restarting the process, causing further delays and underutilized machine capacity.

Phased Implementation for Maximum Impact

To maximize efficiency, Three Sigma implemented Skody AI APS in a single production section — focusing on CNC machining, where component availability issues had the greatest impact on costs.

The initial outcomes were transformative: the scheduling process, once taking three to four days, was reduced to just two hours. Schedules are now generated in seconds, allowing employees to analyze resource availability and utilization within the two-hour window, significantly boosting operational efficiency.

Measurable Results

Reduced Scheduling Time and Inventory

Scheduling time dropped from days to hours, and inventory levels decreased by 15%.

ERP Integration for Real-Time Accuracy

Integration with the ERP system enables dynamic, real-time communication, eliminating double entries and reducing errors.

Enhanced Flexibility

Real-time scheduling optimized for CNC constraints enables rapid adjustments to material delays or rush orders.

Synchronized Production

The system aligns production with raw material deliveries and maintains optimal semi-finished product stocks.

Extended Planning Horizon

Planning now covers three weeks instead of one, improving resource utilization through strategies like programming alternative CNC lines.

Improved Communication

Skody's integrated messaging system replaced physical sticky notes, allowing operators to leave detailed notes for each production run, ensuring seamless information sharing across shifts.

"Skody AI APS has revolutionized our scheduling, giving us unmatched flexibility with our customers. We no longer need to lock in schedules for four weeks, telling clients, 'We'd love to take your order, but you'll have to wait due to fixed lead times.' With Skody AI, we've extended our planning horizon to one year and drastically reduced the schedule freeze period, enabling us to respond dynamically to customer needs."

— Ken Frenkel, CEO of Three Sigma Technologies (Kent, WA)

Three Sigma Technologies: Revolutionizing Production Scheduling with Skody AI APS

RESULTSKey Outcomes