An employee is qualified for multiple workstations but is intentionally assigned to work only on one machine during a specific shift. Reasons for this may include short travel distances, well-established workflows, or the employee’s specific experience at that workstation. Those responsible for daily production operations are often aware of such information, but it is not stored in the Advanced Planning and Scheduling (APS) system.
With the new shift management feature, this information can be directly incorporated into the planning process. In this process, production sets the framework within which GANTTPLAN continues to perform automated optimization.
“The shift management feature was developed in response to a specific customer requirement. Originally, the goal was to be able to flexibly adjust shifts to current capacity utilization and the actual order backlog. From this, we developed a more comprehensive solution that now also allows the practical knowledge of those responsible in production to be directly incorporated into planning,” explains Dr. Kirsten Hoffmann, Product Manager at DUALIS.
Flexibly manage staff deployment, additional shifts, and absences
The shift management system displays workstations and the qualified personnel assigned to them in a timeline view. For individual shifts, managers can specify which employees or staff pools may be scheduled for a particular workstation. If, for example, a multi-skilled employee is intentionally not to be assigned to a specific machine during a shift, this assignment option can be excluded. GANTTPLAN takes this requirement into account and further optimizes staffing within the remaining options. For different production areas, such as assembly or the turning shop, separate views can also be created showing the relevant workstations.
Additional capacity can also be incorporated into the schedule at short notice. If, for example, an early shift normally runs from Monday through Friday, a Saturday shift can be activated during periods of high workload. Instead of having to adjust numerous employee calendars individually, the additional capacity is immediately available for scheduling.
Managers can also react immediately to unplanned staff absences. For example, if an employee calls in sick, it may take time for this information to reach the planning system via HR or time-tracking systems. Using shift management, the employee’s available shifts can be deactivated immediately. GANTTPLAN then continues planning based on the actual available capacity.
Closer Integration of Production Planning and Manufacturing Reality
Shift management complements automated production planning by adding an operational control level. This means that short-term decisions made on the shop floor do not need to be permanently stored in master data or shift models in order to be taken into account during optimization.
For DUALIS, this feature also represents a step toward closer integration of production planning and operational workforce scheduling. The GANTTPLAN APS system continues to optimize automatically—but also incorporates the specifications that apply to a specific day or a particular shift.
“Foremen and shift supervisors must be able to exert influence in areas where they know more about the current situation than is recorded in the master data. With shift management, we’re bringing this experiential knowledge from the shop floor even more strongly into the planning process,” says Dr. Kirsten Hoffmann.
About DUALIS GmbH IT Solution
Founded in 1990, DUALIS GmbH IT Solution —a subsidiary of iTAC Software AG and part of the Dürr Group—specializes in the development of software and services related to simulation, process optimization, and production planning. Its product portfolio includes the APS system GANTTPLAN, the 3D simulation platform Visual Components, and the plant layout tool AREAPLAN. DUALIS products are used by numerous large industrial companies and medium-sized industrial firms. Consulting and services for strategic and operational planning round out DUALIS’s range of offerings.
The Dürr Group is a leading global manufacturer of machinery and systems with particular expertise in the technology fields of automation, digitalization, and energy efficiency. Its products, systems, and services enable highly efficient and sustainable manufacturing processes—particularly in the automotive industry, among manufacturers of furniture and wooden houses, as well as in the assembly of medical and electrical products and in battery production. In 2025, the Dürr Group generated revenue of just under €4.2 billion and currently employs approximately 17,500 people at 123 locations in 32 countries.
– – – – –
Related Links
👉 www.dualis-it.de
Photo: DUALIS
