Batch planning and digital process passport
Automated planning and transparent processes for sustainable heat treatment.
Optimize energy costs, promote sustainability
Efficient heat treatment
The hardening and heat treatment industry is under enormous pressure: Rising energy costs and high energy consumption in production urgently require process optimization. At the same time, the demands on CO2-neutral production, making precise and efficient furnace scheduling essential. In an increasingly competitive and regulated industry, solutions are needed that maximize efficiency while consistently meeting sustainability goals.
With our software we make heat treatment smart, sustainable and future-proof.
Your challenge
Reduce complexity – increase efficiency
High energy costs
The sharp rise in energy costs is placing a significant burden on companies, increasing the need to optimize energy efficiency.
CO2 reporting obligation
The increasing reporting requirements regarding sustainability values and CO2 emissions require detailed and traceable documentation for each individual batch.
Optimization of furnace utilization
Inefficient furnace utilization leads to increased energy consumption and unused capacity, which means that savings potential in production remains unused.
Optimized batch planning and process monitoring
To meet these challenges, we rely on a modular solution with two powerful components: the data-driven batch planning tool and the Digital Process Passport. Both modules can independently or in combination be used. That Batch planning tool optimizes the sequence of batches, reduces energy losses and ensures adherence to deadlines. The Digital process passport records and analyses energy and resource data, identifies efficiency potential and enables comprehensive reporting of sustainability values for individual batches.
By combining real-time data analysis, automated planning and sensor-based process monitoring, we enable efficient, sustainable and economical heat treatment – a real added value for companies of all sizes.
Batch planning tool.
An automated scheduling system that calculates the optimal batch sequence. It improves furnace utilization, reduces idle time, and minimizes energy consumption.
Digital process pass.
A tool for the automated collection and verification of energy and CO2 data. It ensures transparency, fulfills reporting obligations, and supports companies on their path to sustainable production.
Your contact person
Do you have any questions?
We have the answers! Our colleague Nikolai Kamenev will be happy to answer all your questions about the batch planning tool and the Digital Process Passport.
Nikolay Kamenev
nikolai.kamenev@aws-institut.de
+49 152 34643 494
Our modules
Efficient planning and transparent documentation
Our technology consists of two modules specifically tailored to heat treatment optimization. Each solution fulfills a specific function – from efficient batch management to the precise recording and analysis of energy and resource data to the transparent documentation of sustainability values. Both modules operate flexibly and can be used individually or in combination as needed to enable comprehensive efficiency improvements and sustainable production.
Maximum efficiency in furnace use.
Our batch planning tool optimizes the sequence of production batches in real time. The underlying algorithm automatically evaluates orders based on criteria such as on-time delivery, energy efficiency, and furnace utilization. Based on this, the optimal sequence is created that both adheres to the production schedule and minimizes energy consumption. The tool also takes into account specific recipe requirements and restrictions of individual batches. It offers both dynamic and manual scheduling adjustments to ensure maximum flexibility.
Your Benefits.
Maximized oven utilization: Optimized occupancy reduces idle times and minimizes energy consumption.
Compliance with delivery deadlines: On-time order processing through prioritized, automated planning.
Cost reduction: Reducing production costs through optimized resource use and less energy waste.
- Flexibility: The tool can be flexibly adapted to production requirements and minimizes manual intervention.
Functionality.
The batch planning algorithm takes several key criteria into account:
On-time delivery: The algorithm optimizes the sequence of batches to ensure that all delivery deadlines are met.
Batch utilization: Planning ensures that furnace capacities are used efficiently to minimize idle times.
Energy saving: The software places batches with small temperature differences one after the other, minimizing energy consumption and maximizing resource utilization.
Consideration of restrictions: The tool takes into account recipe requirements and production restrictions such as temperature or time specifications.
- Flexible customization: Manual changes are possible to integrate spontaneous requirements and make adjustments.
The result: An intuitive dashboard that instantly provides you with an optimized, actionable batch sequence and helps you continuously improve your production processes.
Focus on sustainability values and energy efficiency.
The Digital Process Passport ensures seamless, data-based documentation and analysis of resource usage in real time. By continuously tracking energy consumption and CO2 emissions for each batch, the Process Passport enables precise monitoring of sustainability goals. The tool collects relevant key performance indicators and makes them available for analysis and optimization of production processes. With this solution, companies can ensure that all sustainability requirements are met and resource usage is effectively managed.
Your Benefits.
Transparent flights: Every step of resource usage is traceable, allowing companies to check their efficiency at any time.
Sustainability: The tool helps to reduce CO2 emissions and achieve CO2-neutral production targets.
Process Optimisation: Real-time analysis continuously optimizes processes and avoids energy waste.
Compliance: Fulfillment of legal reporting obligations and proof of resource efficiency to stakeholders and regulatory authorities.
Functionality.
- Real-time data analysis: The process pass continuously collects energy and resource data for each batch and analyzes it in real time.
Transparent documentation: All collected data is summarized in a dashboard and can be viewed at any time.
CO2 and energy monitoring: Automatic calculation and monitoring of CO2 emissions and energy consumption of each batch.
Reporting: The tool facilitates the creation of sustainability reports by providing relevant data in a structured manner.
Innovative process control for a sustainable future.
Our solution combines the Batch planning tool with the Digital process passport into a seamless system that takes your heat treatment processes to a new level of efficiency. By integrating both modules, all relevant production data is combined and processed in real time. This enables automated, data-driven batch planning that takes on-time delivery, capacity utilization, and energy efficiency into account.
Your Benefits.
Holistic process optimization: The integration of both modules enables a complete overview of all relevant production data – from furnace usage to resource consumption.
Automated planning and real-time data: Optimize your batch planning with automated, data-based recommendations that ensure both on-time delivery and energy efficiency.
Sustainability and Compliance: The Digital Process Passport ensures the complete recording and reporting of energy consumption and CO2 emissions, so that you can easily comply with legal requirements and at the same time achieve your sustainability goals.
The combination of both modules enables efficient production planning, reduces energy consumption and CO2 emissions, and ensures compliance with legal CO2 reporting requirements. This increases your competitiveness and achieves sustainable, cost-effective production.
Our expertise
Through our work within the research project OekoProOf We have extensive expertise in developing digital solutions for energy optimization and Resource sustainability We have developed systems that Energy consumption and CO2 emissions precisely capture and optimize – core functions that are also present in our Digital process passport and the Batch planning This experience enables us to develop tailor-made solutions for a sustainable and efficient heat treatment offer.
Nikolay Kamenev, contact person for batch planning and digital process passport, works as a Digitalization Professional at the August-Wilhelm Scheer Institute. Together with colleagues, he has been responsible for the conception and implementation of the Digital process passport in a Publications (Alt et al., 2023). Thanks to his expertise and the interdisciplinary collaboration at the institute, we are able to develop innovative solutions to optimize heat treatment and make it more efficient and sustainable.
Interested? Then schedule a free initial consultation now.
Nikolay Kamenev
Email: Nikolai.Kamenev@aws-institut.de
Phone: + 49 152 34643 494
What our participants say
Achieving more together
The intrapreneurship program of the August Wilhelm Scheer Institute is an outstanding initiative that promotes entrepreneurial thinking and action within the company. In practical workshops and through targeted coaching, employees are enabled to develop innovative ideas and implement them independently. The combination of theoretical knowledge and practical application creates a dynamic learning environment that strengthens creativity and personal responsibility. This program is a must for companies that want to increase their innovative power from within.
Person?
Immerse yourself flexibly and expand your know-how – anytime, free of charge.
Our webinars on demand
Scientific and talent-centered
Our success model
We offer Best in class in the scientific and talent-centric incubation.
The teams work on the current and future challenges of the company during the program. This not only strengthens the entrepreneurial potential of each individual, but also the innovative power of the company for long-term corporate success.
Part of our work is documented in the current Intrapreneurship Monitor. Almost 500 companies from Germany were surveyed in 2023 about how they set up intrapreneurship activities in their company and what obstacles and challenges had to be overcome. A particular focus was placed on the ICT industry. Together with the University of Bayreuth we show how successful intrapreneurship programs have to be designed.