{"id":12060,"date":"2025-02-27T09:04:54","date_gmt":"2025-02-27T08:04:54","guid":{"rendered":"https:\/\/www.dualis-it.de\/en\/?p=12060"},"modified":"2025-03-11T10:43:34","modified_gmt":"2025-03-11T09:43:34","slug":"ganttplan-revolutionizes-toolmaking-at-johannes-lubbering-gmbh","status":"publish","type":"post","link":"https:\/\/www.dualis-it.de\/en\/ganttplan-revolutionizes-toolmaking-at-johannes-lubbering-gmbh\/","title":{"rendered":"Success Story: GANTTPLAN Revolutionizes Toolmaking at Johannes L\u00fcbbering GmbH"},"content":{"rendered":"\n<h2 class=\"wp-block-heading\"><strong>APS in Interaction With ERP and Workshop Management<\/strong><\/h2>\n\n\n\n<p><strong>At Johannes L\u00fcbbering GmbH, the APS (Advanced Planning and Scheduling) system GANTTPLAN integrates seamlessly with the ERP system \u201cAPplus\u201d and its workshop control system. Together, GANTTPLAN and APplus create an ideal synergy in toolmaking, resulting in reduced setup, production, and delivery times. This integration enhances reliability, transparency, and efficiency, leading to high customer satisfaction as a crucial competitive advantage.<\/strong><\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Key Highlights<\/h2>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p><strong>Inititual Situation:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Challenges with transparency in planning\/scheduling and in managing capacity bottlenecks.<\/li>\n\n\n\n<li>Delivery delays despite overtime, excessive setup times, high personnel and material costs, and inefficient machine utilization.<\/li>\n<\/ul>\n\n\n\n<p><strong>Special Features:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Creation of a pre-sales model with live data from approximately 12,000 orders.<\/li>\n\n\n\n<li>Seamless integration of GANTTPLAN into the existing ERP system and workshop control system via SQL interfaces.<\/li>\n\n\n\n<li>Extensive machinery and above-average vertical integration with often small lot sizes.<\/li>\n\n\n\n<li>Process optimization through planning of CAD\/CAM programming.<\/li>\n<\/ul>\n\n\n\n<p><strong>Benefits:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Planning and control of 110 machines and approximately 10,000 orders per working week.<\/li>\n\n\n\n<li>Reduction of throughput time by 50 to 80 percent.<\/li>\n\n\n\n<li>Sustainable optimization of production sequence, machine utilization, and setup times.<\/li>\n\n\n\n<li>Greater transparency and planning reliability throughout the entire order processing chain.<\/li>\n\n\n\n<li>Cost optimization through an integrated employee scheduling module.<\/li>\n<\/ul>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.dualis-it.de\/en\/experience-live\/demo\/\" target=\"_blank\" rel=\"noreferrer noopener\">Book Your Exclusive Live Demo!<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">L\u00fcbbering &#8211; High-Precision Toolmaking \u2018Made in Germany\u2019<\/h2>\n\n\n\n<p><a href=\"https:\/\/www.luebbering.de\/en\/\" target=\"_blank\" rel=\"noreferrer noopener\">Johannes L\u00fcbbering GmbH<\/a> is a globally active, innovative family business. Based in Herzebrock-Clarholz in East Westphalia, it develops and produces customised high-precision tools for screwdriving and drilling technology for well-known manufacturers in the automotive and aviation industries. With currently around 220 employees, the company can now look back on over 80 years of history.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"1049\" height=\"700\" src=\"https:\/\/www.dualis-it.de\/wp-content\/uploads\/Luebbering-Headquarter-1049x700.jpg\" alt=\"Johannes L\u00fcbbering GmbH headquarters in Herzebrock-Clarholz (Germany)\" class=\"wp-image-17505\" srcset=\"https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Luebbering-Headquarter-1049x700.jpg 1049w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Luebbering-Headquarter-800x534.jpg 800w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Luebbering-Headquarter-768x513.jpg 768w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Luebbering-Headquarter-1536x1025.jpg 1536w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Luebbering-Headquarter.jpg 1840w\" sizes=\"(max-width: 1049px) 100vw, 1049px\" \/><figcaption class=\"wp-element-caption\">Johannes L\u00fcbbering GmbH headquarters in Herzebrock-Clarholz (Germany)<\/figcaption><\/figure>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Initial Situation in 2011: Lack of Satisfaction and Planning Transparency<\/h2>\n\n\n\n<p>Due to the extensive machinery and an above-average vertical range of manufacture exceeding 90%, combined with small lot sizes (fewer than 10 pieces) and the resulting high level of planning and scheduling complexity, the decision was made in 2012 to introduce a production control center. Without an ingenious planning solution, the situation had deteriorated in the preceding months: numerous orders from different toolmaking business areas, lack of transparency, capacity bottlenecks, delays despite overtime hours, weak set-up management, elevated personnel and material costs, and inefficient machine utilization. This was the status quo at the time \u2013 a thoroughly critical competitive situation, even though the L\u00fcbbering Group had already established a pleasingly stable market position thanks to patented in-house developments and a clever corporate policy.<\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Convincing Planning Performance: Decision in Favour of GANTTPLAN<\/h2>\n\n\n\n<p>The decision to introduce an APS system was followed by a structured selection process. Several arguments favored the <a href=\"https:\/\/www.dualis-it.de\/en\/products\/ganttplan-advanced-planning-and-scheduling-system\/\" target=\"_blank\" rel=\"noreferrer noopener\">GANTTPLAN <\/a>APS solution from DUALIS: its control station can be easily and closely integrated into the ERP system via SQL interfaces, allowing for the management of large data volumes without issues. Additionally, GANTTPLAN excelled in scheduling for limited capacities, displaying order networks, and offering flexible planning for machines, personnel, and tools. Existing optimization parameters for setup optimization and the overall price-performance ratio further supported the choice of GANTTPLAN.<\/p>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-columns is-layout-flex wp-container-core-columns-is-layout-28f84493 wp-block-columns-is-layout-flex\">\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"920\" height=\"613\" src=\"https:\/\/www.dualis-it.de\/wp-content\/uploads\/Produktionsplanungsbuero_Johannes_Luebbering_GmbH.jpg\" alt=\"Production planning office at Johannes L\u00fcbbering GmbH\" class=\"wp-image-17509\" srcset=\"https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktionsplanungsbuero_Johannes_Luebbering_GmbH.jpg 920w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktionsplanungsbuero_Johannes_Luebbering_GmbH-800x533.jpg 800w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktionsplanungsbuero_Johannes_Luebbering_GmbH-768x512.jpg 768w\" sizes=\"(max-width: 920px) 100vw, 920px\" \/><figcaption class=\"wp-element-caption\">Production planning office at Johannes L\u00fcbbering GmbH<\/figcaption><\/figure>\n<\/div>\n\n\n\n<div class=\"wp-block-column is-layout-flow wp-block-column-is-layout-flow\">\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"920\" height=\"613\" src=\"https:\/\/www.dualis-it.de\/wp-content\/uploads\/Produktion_Johannes_Luebbering_GmbH.jpg\" alt=\"A look at the production at Johannes L\u00fcbbering GmbH\" class=\"wp-image-17510\" srcset=\"https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktion_Johannes_Luebbering_GmbH.jpg 920w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktion_Johannes_Luebbering_GmbH-800x533.jpg 800w, https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Produktion_Johannes_Luebbering_GmbH-768x512.jpg 768w\" sizes=\"(max-width: 920px) 100vw, 920px\" \/><figcaption class=\"wp-element-caption\">A look at the production at Johannes L\u00fcbbering GmbH<\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p>Oliver Nienaber, Head of Processing Planning at Johannes L\u00fcbbering GmbH, states: &#8220;Only DUALIS was able to create a pre-sales model from our live data of around 12,000 orders to prove functional suitability \u2013 and that in just a few days. Moreover, the chemistry was just right.&#8221;<\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Big Plus: Integration Into ERP System<\/h2>\n\n\n\n<p>GANTTPLAN could be perfectly integrated into the APplus ERP system from Asseco, already in use at L\u00fcbbering in 2012. The production control center was placed between the ERP system and the workshop control system, also provided by Asseco. This setup ensures that master and transaction data remain in the ERP system, while GANTTPLAN handles <a href=\"https:\/\/www.dualis-it.de\/en\/production-scheduling-software-9-must-haves-for-a-flawless-workflow\/\" target=\"_blank\" rel=\"noreferrer noopener\">detailed planning and optimization<\/a>. The ERP system continues to play the leading role, preventing data redundancies and simplifying maintenance efforts.<\/p>\n\n\n\n<p>Pre-scheduled production orders from APplus are typically transferred to the GANTTPLAN system once a day via the SQL interface. Here, they are optimized using the automatic planning function according to available capacities and defined target criteria. After the planning run, the APS transfers the finely scheduled work processes, allocated to approximately 185 resources, back to the ERP system. Subsequently, all order information reaches the production employees via the workshop control system.<\/p>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"cite-item-wrap image-medium image-left\">\n<div class=\"cite-item-image\">\n<div class=\"cite-item-image-wrap\">\n<img decoding=\"async\" width=\"144\" height=\"192\" src=\"https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Toennies_Tobias__Luebbering_3zu4.jpg\" class=\"attachment-medium size-medium wp-post-image\" alt=\"Tobias T\u00f6nnies von L\u00fcbbering gratuliert DUALIS zum Jubil\u00e4um\" \/><\/div>\n<\/div>\n<div class=\"cite-item-content\">\n<div class=\"teaser-text space-bottom-small\">\n<!-- wp:paragraph -->\n<p>\"The combination of the ERP system, GANTTPLAN, and workshop control has enabled us to optimize the production sequence and machine utilization, greatly improving adherence to deadlines. Planning and synchronization times have been significantly reduced. By regularly updating GANTTPLAN, we are constantly reducing planning and synchronization times, thereby increasing performance.\"<\/p>\n<!-- \/wp:paragraph -->\n\n<!-- wp:paragraph -->\n<p><\/p>\n<!-- \/wp:paragraph --><\/div>\n<p>\nTobias T\u00f6nnies<br\/>\nCEO, Johannes L\u00fcbbering GmbH<\/p>\n<\/div>\n<\/div>\n\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button is-style-outline is-style-outline--1\"><a class=\"wp-block-button__link has-blue-light-color has-white-background-color has-text-color has-background has-link-color has-border-color has-blue-light-border-color wp-element-button\" href=\"https:\/\/www.dualis-it.de\/en\/products\/ganttplan-advanced-planning-and-scheduling-system\/\" style=\"border-width:1px\" target=\"_blank\" rel=\"noreferrer noopener\">Get to Know GANTTPLAN!<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Rapid Success: Scepticism Gave Way to Enthusiasm<\/h2>\n\n\n\n<p>The implementation of GANTTPLAN to control 110 machines took around six to seven months in 2012. &#8220;It took us the longest to prepare our master data and parts lists,&#8221; says Oliver Nienaber. Today, L\u00fcbbering processes around 10,000 orders per working week. In this respect, there is theoretically no upper limit with GANTTPLAN. Oliver Nienaber explains: &#8220;Initially, there were concerns about introducing an APS. However, this quickly changed. Each of us still experiences the concrete benefits ourselves every day.&#8221;<\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">10 Years of APS Use: Diverse Process Optimisations and Smart Employee Scheduling<\/h2>\n\n\n\n<p>After the introduction of GANTTPLAN, L\u00fcbbering restructured its pre-production activities, considering various planning parameters. This resulted in complete transparency throughout the entire order processing chain. Workers now have a constant overview of their orders and the overall context via workshop terminals. For over 10 years, GANTTPLAN has been automatically calculating efficient production sequences and transferring the optimized production plans directly to the control system. This increased transparency allows for minimized setup times through bundling.<\/p>\n\n\n\n<p>In the following years, additional tools such as supplementary tool management software were introduced, reducing throughput times by 50 to 80 percent compared to the pre-APS situation. Over time, L\u00fcbbering utilized more GANTTPLAN functions. For instance, the personnel planning module for <a href=\"https:\/\/www.dualis-it.de\/en\/employee-scheduling-software\/\" target=\"_blank\" rel=\"noreferrer noopener\">employee scheduling<\/a> has been fully integrated into the planning system, enabling foremen to see which order is to be processed on which machine at any given time.<\/p>\n\n\n\n<p>Moreover, the introduction of <a href=\"https:\/\/www.dualis-it.de\/en\/production-scheduling-software-9-must-haves-for-a-flawless-workflow\/#More_than_just_machines_Why_every_production_resource_and_tool_matters_for_scheduling\" target=\"_blank\" rel=\"noreferrer noopener\">&#8220;production resources&#8221;<\/a> (tools, devices, test equipment, etc.) as a planning-relevant optimization in GANTTPLAN brought many advantages. Additionally, scheduling CAD\/CAM programming as an operation upstream of cutting production was another significant step towards process optimization.<\/p>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"cite-item-wrap image-medium image-left\">\n<div class=\"cite-item-image\">\n<div class=\"cite-item-image-wrap\">\n<img decoding=\"async\" width=\"450\" height=\"600\" src=\"https:\/\/www.dualis-it.de\/en\/wp-content\/uploads\/Oliver_Nienaber_Johannes_Luebbering_GmbH_Portrait_450x600px.jpg\" class=\"attachment-medium size-medium wp-post-image\" alt=\"\" \/><\/div>\n<\/div>\n<div class=\"cite-item-content\">\n<div class=\"teaser-text space-bottom-small\">\n<!-- wp:paragraph -->\n<p>\"With the introduction of GANTTPLAN and the resulting process optimizations, we have significantly reduced set-up and production times. The terminal-controlled production system also enhances transparency and safety. Together, these systems have greatly shortened our delivery times.\"<\/p>\n<!-- \/wp:paragraph --><\/div>\n<p>\nOliver Nienaber<br\/>\nHead of Processing Planning, Johannes L\u00fcbbering GmbH<\/p>\n<\/div>\n<\/div>\n\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button is-style-outline is-style-outline--2\"><a class=\"wp-block-button__link has-blue-light-color has-white-background-color has-text-color has-background has-link-color has-border-color has-blue-light-border-color wp-element-button\" href=\"https:\/\/www.dualis-it.de\/en\/products\/ganttplan-advanced-planning-and-scheduling-system\/\" style=\"border-width:1px\" target=\"_blank\" rel=\"noreferrer noopener\">Get to Know GANTTPLAN!<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Effect: Goals Achieved<\/h2>\n\n\n\n<p>Today, those responsible for planning and scheduling use GANTTPLAN to oversee and control the entire order processing. This ensures planning stability and smoother production and assembly from an internal perspective, while enhancing customer satisfaction externally. &#8220;Many orders are good. Even more orders are better. But the best scenario is when you can process all orders reliably and swiftly, ensuring customer satisfaction,&#8221; summarizes Tobias T\u00f6nnies, Managing Director of Johannes L\u00fcbbering GmbH.<\/p>\n\n\n\n<div style=\"height:20px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<h2 class=\"wp-block-heading\">Outlook: Automation in the Milling Area and 24\/7 Assembly<\/h2>\n\n\n\n<p>The next step involves using GANTTPLAN to progressively automate the milling area in toolmaking and plan the associated tools and clamping devices accordingly. The goal is to load the machining centers 24\/7 and keep them running optimally. At the same time, the digital provision of information for the production processes will be further optimized.<\/p>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p>[This article was originally published in 2012 and was updated in May 2024]<\/p>\n\n\n\n<div style=\"height:30px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<div class=\"wp-block-buttons is-layout-flex wp-block-buttons-is-layout-flex\">\n<div class=\"wp-block-button\"><a class=\"wp-block-button__link wp-element-button\" href=\"https:\/\/www.dualis-it.de\/en\/contact\/contact-form\/\" target=\"_blank\" rel=\"noreferrer noopener\">Contact Us For More Information!<\/a><\/div>\n<\/div>\n\n\n\n<div style=\"height:100px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n","protected":false},"excerpt":{"rendered":"<p>APS in Interaction With ERP and Workshop Management At Johannes L\u00fcbbering GmbH, the APS (Advanced Planning and Scheduling) system GANTTPLAN integrates seamlessly with the ERP system \u201cAPplus\u201d and its workshop control system. Together, GANTTPLAN and APplus create an ideal synergy in toolmaking, resulting in reduced setup, production, and delivery times. This integration enhances reliability, transparency,<\/p>\n","protected":false},"author":59,"featured_media":17505,"comment_status":"open","ping_status":"open","sticky":false,"template":"template-page-blogpost.php","format":"standard","meta":{"inline_featured_image":false,"advgb_blocks_editor_width":"","advgb_blocks_columns_visual_guide":"","footnotes":""},"categories":[162,598],"tags":[],"class_list":["post-12060","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog","category-erfolgsgeschichten"],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v24.8.1 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>Production Planning in Toolmaking at Johannes L\u00fcbbering<\/title>\n<meta name=\"description\" content=\"Optimisation of production sequences, machine utilisation and set-up times in toolmaking \u2713 L\u00fcbbering GmbH relies on APS software GANTTPLAN.\" \/>\n<meta name=\"robots\" content=\"index, follow, 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