Three Sigma Technologies: Revolutionizing Production Scheduling with Skody AI APS
How a precision aerospace manufacturer transformed their operations from Excel chaos to AI-powered efficiency.
15%
Reduction in production delays
Days → Seconds
Scheduling time
1 Week → 1 Year
Planning horizon
15%
Decrease in inventory levels
About Three Sigma Technologies
Based in Kent, Washington, Three Sigma Technologies specializes in precision machining and component manufacturing for the aerospace industry. Working with suppliers serving aerospace industry giants, the company operates in a demanding environment where meeting customer expectations is paramount.
The company's complex production processes required sophisticated scheduling solutions to align production schedules with material availability and reduce inventory while maintaining the highest quality standards.
Implementation Goals
- Reduce production delays by optimizing scheduling
- Adapt schedules dynamically to machine availability and material delays
- Streamline production planning for greater efficiency
- Replace Excel-based scheduling with automated tooling
The Challenge: Inefficient Excel-Based Scheduling
Three Sigma's complex production processes initially relied on Excel, which fell short for advanced production planning. The lack of a standardized scheduling approach led to inconsistent project quotes. Newer team members struggled to produce reliable estimates, relying heavily on the intuition of senior staff—creating bottlenecks and single points of failure.
Reliance on inefficient, Excel-based scheduling
Inconsistent project quotes and deliverables
Heavy dependence on 'tribal knowledge' of senior staff
Four-day turnaround for production plans
Frequent material delays from aerospace suppliers
Physical 'sticky' notes for operator communication
The Solution: Skody AI APS
To maximize efficiency, Three Sigma implemented Skody AI APS in a phased approach, focusing first on precision machining where component availability issues had the greatest impact on costs.
Reduced Scheduling Time
Scheduling time dropped from 3-4 days to just seconds, with analysis completed within 2 hours.
15% Inventory Reduction
Optimized scheduling led to a 15% decrease in inventory levels.
ERP Integration
Real-time data accuracy through dynamic ERP integration, eliminating double entries.
Extended Planning Horizon
Planning now covers up to 1 year instead of just 1 week, improving resource utilization.
Improved Communication
Replaced physical sticky notes with integrated messaging for seamless shift handoffs.
Enhanced Flexibility
Real-time scheduling enables rapid adjustments to material delays or rush orders.
"Skody AI APS has transformed how we approach production scheduling. What used to take days now takes seconds, and we can plan months ahead instead of just a week. The impact on our operations has been remarkable."
Ken Frenkel
CEO, Three Sigma Technologies
Ready to Transform Your Production Scheduling?
See how Skody AI can deliver similar results for your manufacturing operations.
Book a Demo