Manufacturing processes

We use a range of tools and systems across all our departments and sites to ensure that our processes are as efficient, effective and lean as possible.

What if…? Scenario Planning

By using the What If…? approach, we are able to translate our business plan – including forecasting demand – into a viable production plan that uses real and provisioning orders.

We use What If…? across all Hayward Tyler’s operations and sites for a broad range of functions, including planning for

  • Headcount
  • Load and capacity
  • Capex

What If…? is also used for a range of calculations – among them work-in-progress and parts storage – and counts, including parts and tooling, purchase ordering, and receipt entry.  Other functions also include…

  • Financial budget validation
  • Support revenue forecasting
  • Forward load analysis
  • Holiday management
  • Production lead times
  • Factory parts flow
  • Product launches

Sales and operational planning analytics (SOP)

Using SOP links our sales and production departments and allows us to avoid shortages and poor resources allocation as well as costly last-minute scheduling and expediting. With SOP, we can produce a master schedule and generate the outputs we need for informed decision-making.

Our What If…? and SOP functions integrate, allowing us to use both historical data and current market insight to deliver true sales intelligence. With a more accurate and reliable analysis of past and present business scenarios we are better able to decide how best to deliver our products and services and determine potential revenue.

Witness simulation

With our Witness simulation software, we are able to create statistically accurate models capable of representing how real-life systems would respond in different situations. We can then more accurately answer What If…? questions without needing to disturb the real-life systems we are emulating.

We can also use discrete event simulation to model individual events that occur at given times, and can take into account associated resources and constraints and see how they interact. There is scope to introduce simulated randomness and variability to explore how a real process — such as a manufacturing flow line — would respond in particular circumstances.

Witness offers significant advantages over real-life experiments in terms of cost, time, and the capacity for repetition. This is of special benefit where there is variability, disruption or layers of complexity.

Our Lean manufacturing and enhanced reporting capabilities deliver benefits throughout our supply chain.
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