the case study in a nutshell


Related Solution
Digital Production Planning

Learn More
This client is an agile and pragmatic pharmaceutical Company whose business is suffering from excess of stock, low equipment saturation and inadequate service level. A situation that in time could seriously jeopardise its leading position within the Italian and European industry. To face this risk, we have initially identified the main gaps in the IT systems and master data management and planned a set of quick actions to improve the overall data quality and information flows. Then we have implemented an AI-based production planning tool that achieves better saturation and better service level than a human performing the same task, in a fraction of the time.

The new scheduling tool achieves +5% equipment utilization and +8% service level on an average plan

AI-scheduling allows to reduce by -90% the time spent on manual planning operations

Optimized plans can reduce stock utilization by 5% possibly saving >1M€ each year.

We tell you a story


Customer Profile

Amplifon S.p.A. is an Italian company that deals with the design, application and marketing of hearing aids. It is present in 29 countries and on all 5 continents, with more than 11,000 points of sale and around 16,000 employees and collaborators, and a turnover of 1.4 billion Euros. With the acquisition of GAES plant (Barcelona, Spain) in 2018, - has consolidated its worldwide leadership reaching a global market share of 11% of the retail hearing care market.



To design, validate and formalize a methodology in the Barcelona plant expandable to the whole EMEA region, with the following goals:

  • develop an earmolds integrated EMEA supply chain, capable of up to 600k earmolds per year;
  • reduce cost by 4.6 mEUR per year by improving sourcing and production effectiveness and efficiency, lowering the per full industrial cost from 13.9 to 10 EUR/unit;
  • maintain/improve current Service Level



We have developed from scratch a Digital Twin in order to:

  • simulate all possible future scenarios, obtaining precise calculation of lead times, service levels and saturations;
  • validate the re-layout/material flow hypothesis before any intervention;
  • find the optimal configuration in terms of allocated FTEs and shifts for any possible demand which yield maximal throughput.

We have also designed an OCR-based real-time digital traceability and jobs scheduling system, integrated with the existing ERP, for guaranteeing the optimal scenario in case of unpredictable demand and jobs priorities.



Customer profile

A leading API manufacturer based in Italy. Its therapeutic classes are for anticancer treatments, steroids, psychotropics and non-beta lactam antibiotics, as well as for veterinary use.



  • Equipment saturation and service level is unsatisfactory due to very complex production environment and huge number of constraints.
  • Planning & scheduling scheduling is still performed manually and is not properly supported by existing tools.
  • Master data accuracy and completeness is insufficient.


Our solution

  • Performed an in-depth analysis of the production planning processes and highlighted the main gaps in the process
  • Designed and implemented a completely new AI-based digital tool for production planning to fully replace manual planning
  • Planned an action roadmap to improve overall data quality and management

Want to know more?

Whether you have any questions or need more info, we would be happy to help!


Contact US

for more information write to


follow us on Linkedin
and find out our latest news