Maximize Throughput. Minimize Waste. Optimize Every Line.
We optimize production schedules, minimize changeover times, and balance workloads across multiple lines—helping manufacturers increase throughput while reducing costs and waste.
Strategic Duo Portrait
Owner B (foreground) in "Approachable Lean" + Owner A (background) in "Power Cross"
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Who Are Our Services For?
Food & Beverage Manufacturers
Producers managing perishable ingredients, strict hygiene changeovers, batch sequencing, and seasonal demand spikes across multiple production lines.
Pharmaceutical & Chemical Companies
Facilities with regulatory compliance requirements, cleanroom scheduling, batch traceability, and complex multi-stage production workflows.
Automotive Parts Suppliers
Tier 1 and Tier 2 suppliers managing just-in-time delivery commitments, multi-variant production, and tight OEM deadlines across dozens of machine centers.
Packaging & Print Manufacturers
Companies dealing with frequent job changes, color sequencing, die/plate setup times, and high-mix low-volume order profiles.
Metal & Plastics Fabricators
Job shops and contract manufacturers balancing diverse customer orders, shared CNC machines, and complex routing through multiple work centers.
Electronics & Assembly Operations
Facilities coordinating SMT lines, manual assembly stations, component availability, and testing bottlenecks in high-precision environments.
The Reality in Manufacturing Operations
Most manufacturing planners rely on experience, gut feeling, and spreadsheets to sequence production orders. The result: excessive changeover times, unbalanced lines, missed delivery dates, and inventory that's either too much or too little.
ERP systems tell you what needs to be produced, but not how to sequence it optimally. The gap between "what to make" and "in what order, on which line, at what time" is where millions in efficiency are lost every year.
Changeovers eat up hours of productive capacity every day
Some lines run overtime while others sit idle
Production plans based on planner intuition, not optimization
Demand fluctuates but production schedules are rigid and slow to adapt
Why Virtual Optima?
We specialize in the mathematical optimization of production scheduling—the hardest and highest-impact problem in manufacturing operations.
"The Architect" Pose
Owner A, Technical Lead - The Architect
Direct gaze, hands on laptop, organized algorithm display, clean workspace
Mathematical Rigor
We formulate your production scheduling as a mathematical optimization problem, finding provably better solutions than heuristic or rule-based approaches.
Real Factory Constraints
Our models handle the constraints that generic tools ignore—sequence-dependent changeovers, shared tooling, split lots, campaign production, and maintenance windows.
Measurable ROI
Every solution we deliver comes with quantifiable impact metrics: reduced changeover time, increased throughput, lower inventory costs, and improved on-time delivery.
ERP Integration Ready
Our optimization layer sits on top of your existing ERP/MES system, enhancing your planning without replacing your infrastructure.
Practical Examples from the Industry
Optimization Solutions in Action
Challenge: Changeover Time Waste
Switching between products means stopping production, cleaning equipment, and adjusting settings—wasting 1-4 hours per change.
Solution
We determine the optimal production sequence that minimizes changeovers and groups similar products together, keeping your lines running longer.
Results
- <span class='hand-drawn-highlight variant-1'>47% reduction</span> in changeover time
- <span class='hand-drawn-highlight variant-2'>31% throughput increase</span>
- <span class='hand-drawn-highlight variant-3'>€2.3M annual</span> savings
- More products with same resources
Expert Note: Most systems miss optimizations like this because they don't account for multiple constraints simultaneously.
Challenge: Meeting Fluctuating Demand
Customer orders vary daily but production runs are inflexible, leading to stockouts or excess inventory eating up warehouse space.
Solution
Our system creates dynamic production plans that match demand patterns while balancing inventory costs and machine capacity.
Results
- <span class='hand-drawn-highlight variant-1'>99% order fulfillment</span> rate
- <span class='hand-drawn-highlight variant-2'>35% reduction</span> in inventory costs
- No stockouts on key products
- Just-in-time production achieved
Expert Note: Most systems miss optimizations like this because they don't account for multiple constraints simultaneously.
Challenge: Maintenance Scheduling
Machines need regular maintenance but stopping production loses money—timing is critical to minimize impact.
Solution
We schedule preventive maintenance during natural production gaps and low-demand periods, protecting equipment without sacrificing output.
Results
- Zero unplanned downtime
- 28% longer equipment lifespan
- Maintenance during optimal windows
- Production targets consistently met
Expert Note: Most systems miss optimizations like this because they don't account for multiple constraints simultaneously.
Challenge: Multi-Line Balancing
Some lines run overtime while others sit idle, creating bottlenecks and uneven costs across your facility.
Solution
Our optimizer distributes work evenly across all production lines based on capacity, speed, and product compatibility.
Results
- Balanced workload across all lines
- <span class='hand-drawn-highlight variant-3'>23% reduction</span> in overtime costs
- Eliminated bottlenecks
- Consistent output across shifts
Expert Note: Most systems miss optimizations like this because they don't account for multiple constraints simultaneously.
Let's Work Together!
From initial analysis to optimized production – a clear, proven process.
"The Welcome" Pose
Owner B, Business Expert
Seated, leaning forward, warm meeting space with coffee - inviting & accessible
Initial Consultation
We analyze your production environment, identify bottlenecks, and quantify the optimization potential in your scheduling and sequencing.
Modelling
We build a mathematical model of your production system—machines, changeovers, constraints, and objectives—and generate an optimized plan.
Implementation & Testing
We integrate the optimizer with your ERP/MES, validate with production teams on the shop floor, and refine based on real output data.
Optimization & Support
Ongoing monitoring, re-optimization for changing product mixes, and support to ensure sustained performance improvements.
Typical Project Timeline
Initial results within 2-4 weeks | Full implementation in 6-8 weeks
FAQ
Everything you need to know about production optimization.
Which manufacturing environments do you support?
We work with discrete manufacturing, process manufacturing, batch production, and hybrid environments. Whether you run a single line or a multi-plant operation, our models adapt to your setup.
How does this integrate with our ERP system?
We work alongside your existing ERP (SAP, Oracle, Microsoft Dynamics, etc.) by consuming order and resource data and returning optimized schedules. No ERP replacement needed.
How quickly will we see results?
Most clients see measurable improvements within the first optimized production cycle. Typical projects deliver initial results within 2–3 months of kickoff.
Can you handle sequence-dependent changeovers?
Yes—this is one of our core strengths. We model the exact changeover time and cost between every product pair and optimize the sequence to minimize total changeover impact.
What if our product mix changes frequently?
Our system is designed for dynamic environments. When your order book changes, the optimizer re-calculates the best schedule based on current demand, capacity, and constraints.
What does the collaboration cost?
Pricing depends on the complexity of your production environment and the scope of optimization. We provide a transparent quote after the initial analysis. Contact us to discuss your specific situation.
Still have questions?
We're happy to discuss your specific optimization challenges in detail.
Schedule a ConsultationReady to unlock hidden capacity on your production floor?
Tell us about your manufacturing operations. We'll show you exactly where optimization can reduce costs, increase throughput, and eliminate scheduling headaches.
"We personally assess every manufacturing challenge within 24 hours"
— Tim & Reto
"The Partner Guarantee"
Both owners side-by-side
Direct eye contact, warm sincere smiles, standing tall - radical accountability