Hyundai Assan – Seat Production Planning System

Hyundai Assan is an automotive manufacturer with high-speed production lines. For each vehicle moving along these lines, the seats must be ready on time with the correct model, color and equipment information. However, because seat production takes place on a different line from vehicle production, this created a serious synchronization problem. Seats that were late, mixed up or produced incorrectly not only stopped the assembly line but also caused costly chains of errors. Hyundai Assan partnered with us to solve this issue digitally.

Our goal was to develop a planning system that would ensure seat production proceeds fully aligned and dynamically with the vehicle production line.

The solution we developed:

• Vehicle-specific seat data was pulled from order and stock systems and analyzed
• Planning algorithms were developed in Python; seat production order was generated according to real-time production needs
• These algorithms created flexible production plans by considering order status, stock levels and production capacity
• Thanks to the developed interfaces, production operators and planning teams had instant access to the system

The main challenges in seat production planning were:

• Seats incompatible with the vehicle being sent to the assembly line
• Production stoppages due to overstocking or seat shortages
• Inflexible, manual planning processes

With the system we developed: • Production plans can now be updated in real time and adapted to the line • The issue of sending wrong seats to the assembly line has been eliminated • Production flexibility and resource utilization have been greatly improved

After the system was integrated into the production process, the following gains were achieved:

• Seat production planning success rose from around 60% to above 85%
• Production flexibility enabled quick responses to rush orders and changing demands
• Overproduction and scrap rates decreased
• The workload of planning teams decreased, and decision-making processes accelerated