Success with Zinata and QAD Advanced Scheduling

The Highlights

A leading manufacturer of high-performance materials operates in a fast-paced environment where precision and efficiency are critical. An overreliance on manual scheduling processes was limiting their ability to efficiently manage orders, optimize production sequences, and adapt to disruptions. The team knew that adopting a more dynamic and scalable scheduling solution required more than just new technology—it needed the right expertise and a people-centered approach. They turned to Zinata Inc., a trusted partner in driving operational excellence. Zinata didn’t just implement QAD Advanced Scheduling; they worked alongside the client’s team, ensuring planners were empowered with the knowledge, tools, and confidence to make real-time, data-driven decisions. The result? A leaner, more responsive operation that delivers higher efficiency and improved customer service.

The Headlines

• 30% reduction in changeover hours
• Faster, more accurate scheuduling
• Improved response to urgent orders

The Challenge

The client faced several critical hurdles that impacted their ability to optimize production and respond to customer needs efficiently:

• Limited scheduling visibility – Lack of visibility, algorithms, and scenario modeling made decision-making less efficient.
• Complex manual processes – Scheduling was time-consuming, inconsistent, and difficult to standardize, increasing errors and making it difficult to train new resources.
• System integration barriers – Missing material IDs and routing numbers within a custom system hindered system integration and data accuracy.
• Limited ability to respond to change – Without robust scenario planning, adapting to demand changes while maintaining efficiency was difficult.

Solution

Working closely with the client, Zinata developed a structured, data-driven scheduling approach tailored to their production environment. Through hands-on guidance and strategic integration, Zinata transformed the
client’s scheduling, delivering key improvements such as:

• Strategic Product Wheel implementation – QAD Advanced Scheduling provided a structured, repeatable scheduling approach that optimized production sequences and minimized changeovers.
• Automated scheduling & capacity evaluation – Replacing manual scheduling enabled the client to rapidly sequence orders, assess capacity constraints, and allocate resources more efficiently.
• Optimized changeovers & material visibility – Improved ability to handle unexpected demand shifts and supply disruptions with better material visibility and automated changeover optimization.
• Greater flexibility with advanced scenario planning – Planners modeled and compared scheduling scenarios to meet urgent customer requests without compromising production.
• Sustainable & scalable scheduling framework – A structured process that standardized operations and enabled ongoing refinement and expansion of the scheduling model as production needs evolved.
• Intelligent inventory management – Bills of Materials (BOM) integration automated raw material replenishment, ensuring availability and reducing delays.

By leveraging Zinata’s expertise and QAD Advanced Scheduling’s capabilities, the client modernized its scheduling process, enhanced production agility, and drove long-term operational efficiency.

Results

• 30% reduction in changeover hours – By aligning Product Wheels with optimized sequencing, the client significantly reduced changeovers, minimizing downtime and maximizing production efficiency.
• Enhanced scheduling efficiency – Automated sequencing allowed planners to streamline order prioritization, reducing manual effort and improving overall scheduling accuracy.
• Seamless data integration – Reliable order import and export processes ensured data consistency across systems, enabling smoother workflows and reduced risk of errors.
• Real-time, data-driven decision-making – Live tracking and reporting provided actionable insights, allowing the client to make proactive, informed scheduling decisions.

Handling urgent customer orders with agility

The new scheduling capabilities were tested when the client received an urgent, high-priority order with a tight turnaround. Previously, such requests would have required guesswork and last-minute disruptions.

With QAD Advanced Scheduling, the team quickly modeled production scenarios to identify the most efficient way to fulfill the order without compromising existing commitments. Real-time adaptability allowed seamless schedule adjustments, ensuring smooth execution. As a result, the client delivered the order on time while maintaining operational efficiency — demonstrating the power of data-driven scheduling in high-stakes situations.

Conclusion

The client’s journey highlights the transformative power of advanced scheduling in modern manufacturing. By integrating QAD Advanced Scheduling with Zinata’s expertise, they streamlined operations and built a more agile, data-driven production environment.

With optimized scheduling, improved resource management, and greater responsiveness to customer demands, the client is well positioned for long-term success. This strategic investment ensures sustained efficiency, adaptability, and a competitive edge in the evolving manufacturing landscape.