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.