Plan on nominal cycle times — the datasheet speed.
In one real plant the best machine ran at 70% real efficiency and the worst at 11%. The plan treated them as equals.
A plan built on catalog numbers is fiction with a Gantt chart.PRODUCTION PLANNING & SCHEDULING
Your production plan lies to you by 9 a.m.
Not because your planners are bad. Because the plan was built on numbers no machine has ever actually delivered.
THE ARGUMENT
HOW PLANS ARE REALLY BUILT TODAY
The scheduler doesn't see machine health.
A press three days from failure gets loaded like a healthy one. The breakdown doesn't reschedule the plan — it detonates it, and everyone spends the afternoon in Excel.
Scheduling blind to health is scheduling the next fire drill.Planners reconcile ERP vs reality every morning, by hand.
That daily reconciliation IS the work the software was supposed to do. Your most expensive people are human middleware.
If a person retypes it every day, the system doesn't have it — the person does.“Finite capacity scheduling,” configured once.
Constraints set at go-live drift from reality forever after. Finite on paper, infinite in surprises.
Capacity you configured is opinion. Capacity you measured is fact.THE MARKET PLANS THE FACTORY IT WAS PROMISED.
ATHERYA PLANS THE FACTORY YOU ACTUALLY HAVE.
THE PLAN BUILT ON REALITY
Effective capacity, per machine and per recipe.
Observed pieces/hour × availability × health — never the datasheet. A machine at risk carries less load BEFORE it fails.
The shadow plan measures the gap.
Atherya continuously builds the plan it would run — same capacities as yours — and measures the divergence in hours, run after run. That gap is the price of allocating machines without knowing them.
It replans when the world moves.
A line slowing, a bottleneck forming, a breakdown: the brain replans within minutes of the plant's fingerprint changing — not at tomorrow's meeting.
Maintenance lives inside the plan.
Recommended windows are reserved in the schedule where they cost least. Capacity, deadlines and machine health — one context decides.
A ladder, not a leap.
First it shows the better plan. Then it proposes moves you ratify. Then, inside signed guardrails you can revoke in one click, it handles the routine and leaves you the exceptions.
THE EFFICIENCY YOUR PLAN DOESN'T KNOW ABOUT.
Best machine70%
Plant real average47%
Worst machine11%
60,8 %presses' share of open hours · the found bottleneck+5,9%night shift on the same recipe · nobody knew
Read from six years of one real plant's existing data — before install.
Three questions for whoever runs your planning stack:
- 01 · “Where does my plan's cycle time come from — the datasheet, or a measurement?”
- 02 · “What does my scheduler know about machine health? Anything?”
- 03 · “How many planner-hours did reconciling ERP vs reality cost me this week?”
If question three has a number, that number is the product you're missing.
~+25% output ceiling with the same machines and people.
Unchanged-plant scenario, stated assumptions: theoretical ceiling, not a measurement.
QUESTIONS, ANSWERED
No mystery. No theatre.
Does Atherya replace our APS or our planners?
It replaces the reconciliation, not the judgment. Planners stop rebuilding the plan every morning and start ratifying exceptions; your APS/ERP can stay as the record while Atherya keeps it current.
Where does the plan live?
On Atherya's own Board — and, with signed write-back enabled, ratified decisions flow back into SAP automatically and are verified afterwards against your own data.
What if we disagree with a move?
Pin the order — the brain plans around it. Reject a proposal — it remembers, and won't nag the same move again.
What data does it need?
The orders, cycles and machine data you already have. In one plant Atherya read six years of history before the software was installed.
YOUR PLANT · YOUR DATA · THE PROOF
See the plan your plant could actually keep.
Send one month of orders and machine data. We'll show you the gap in hours between your plan and the one your plant can hold. The number does the selling — or it doesn't.
Discover Atherya