Case
STUDIES
Injection Molding Presses
180 employees, 50 presses, 800 molds, 4-shift operation
Optimal scheduling of present employees to currently engaged molds according to their qualifications.
Production and Assembly
250 employees, 3/4-shift operation
Work allocation to workstations based on released orders, present employees, their qualifications, and experienced + newcomer pairs.
Plastic molding plant
40 employees, 4-shift operation
Substitute management across shifts for even coverage without stopping presses.
Manufacturing Plant
290 employees, 3-shift operation
Dynamic supplementation of operations with temporary workers and contractors according to current demand.
Printer
250 employees, 4-shift operation
Reliable coverage of all workstations and elimination of planning errors through optimal utilization of employee capacity and automation of substitute solutions.
Production and Assembly
250 employees, 3/4-shift operation
Work allocation to workstations based on released orders, present employees, their qualifications, and experienced + newcomer pairs.
Manufacturing Plant
290 employees, 3-shift operation
Dynamic supplementation of operations with temporary workers and contractors according to current demand.
Injection Molding Presses
180 employees, 50 presses, 800 molds, 4-shift operation
Optimal scheduling of present employees to currently engaged molds according to their qualifications.
Plastic molding plant
40 employees, 4-shift operation
Substitute management across shifts for even coverage without stopping presses.
Printer
250 employees, 4-shift operation
Reliable coverage of all workstations and elimination of planning errors through optimal utilization of employee capacity and automation of substitute solutions.
Injection Molding Presses
180 employees, 50 presses, 800 molds - complex planning optimization
The Challenge
Initial situation:
- Supervisor arrives 1.5 hours before shift to schedule employees according to qualifications for current molds
- Another hour dedicated to planning lunch breaks for uninterrupted press operation
- End-of-shift reporting to Excel – manual entry of press utilization and downtime
Critical complications:
- 800 molds = 800 qualifications for each of hundreds of employees
- Multi-machine operation – machines don't use full capacity, so employees operate multiple machines simultaneously
- Zero tolerance for downtime – expensive press startup
- Complicated rescheduling during sudden employee absences
Solution with Ai-Mistr
Automatic optimal planning
Intelligent assistance
- Manual adjustments in seconds with instant qualification suggestions
- Real-time display of each present employee's workload
- Error elimination through automatic compatibility checking
Comprehensive optimization
- Automatic lunch break planning without production interruption
- Optimal utilization of employee capacity on multiple machines
- Immediate rescheduling during absences
Achieved Results
Annual savings: 1,041,600 CZK
Dramatic time savings for supervisors:
- 217 hours monthly saved from Excel work
- 86,800 CZK saved on administration (at 400 CZK/hour cost)
Operational benefits:
- Maximum utilization of employee capacity per shift
- Smooth production without stopping presses
- Error-free planning even with 800 different molds
- Unburdened supervisors
Key Benefits
Complexity mastery
800 molds and qualifications without human errors
Zero press downtime
Optimal break and staffing planning
Maximum efficiency
100% utilization of employee capacity
Immediate responses
Rescheduling during absences in seconds
Strategic management
Supervisors focus on production instead of paperwork
Transformation of Supervisors' Workday
Before Ai-Mistr:
Arrival at 4:30 AM for planning until 6:00 AM
One hour planning lunch breaks
Evening Excel data entry
Total 3.5 hours of administration daily
After Ai-Mistr:
Automatic planning in 30 seconds
Immediate adjustments during shift
1.5 hours daily reduction in overtime and 2 hours daily for production management
Conquering the Impossible
Do you have similarly complex production?
Production and Assembly
250 employees - shift planning automation
The Challenge
Key problems:
- Daily hour-long meetings (on each hall = 4h daily) of supervisors and dispatchers for planning workstation coverage based on qualifications and order priorities
- Outdated qualification matrix blocking employee development
- Manual overtime and substitute management through bulletin boards and phone calls
- Risk of production disruption when supervisor familiar with their team is unavailable
- Pairing of assembler and more experienced setter at each workstation
Solution with Ai-Mistr
Planning automation
Integration with existing systems
- Automatic downloading of released orders from SAP
- Synchronization of employees and absences from attendance system
- Immediate notification of errors during manual shift editing
Mobile application for employees
Achieved Results
Annual savings: 1,032,000 CZK
Management time savings:
- 215 hours monthly gained by dispatchers and supervisors
- 86,000 CZK monthly saved on administration (at 400 CZK/hour cost)
Staffing optimization:
- 1.2% more shifts covered by existing employees
- Savings equivalent to 3 additional employees
- Minimum 50,000 CZK savings per recruitment and training
Operational benefits:
- All orders optimally scheduled with deadline compliance
- Elimination of errors leading to downtime
- Substitutability across halls
- Cancellation of half of coordination meetings
- Automatic measurement and reporting of utilization
- Digitalization and regular updating of qualification matrix
Key Benefits
No downtime
Optimal employee placement at machines
Expert supervisor work
Focus on training and problem-solving instead of administration
Greater flexibility
Easy substitutability across teams and halls
Transparent reporting
Automatic measurement of workstation and employee utilization
Happier employees
Simple mobile application for shifts, vacation, and overtime
Would you like to see similar results in your company?
Plastic molding plant
40 employees - shift planning optimization
The Challenge
A plastics press shop with 40 employees in four-shift operation faced daily challenges moving substitutes around to maintain balanced staffing between shifts for non-stop press utilization. The production manager spent a significant portion of time handling administration instead of strategic management.
Key problems:
- Daily manual people-shifting in Excel to maintain even headcount per shift
- Frequent substitutes for vacation and sick leave requiring qualified replacement searches
- Variable production requirements – sometimes 8 people, sometimes 12 according to orders
- Constant calling of agencies and employees to ensure correct staffing
- Loss of time for strategic management and operation development
Solution with Ai-Mistr
Quick deployment
- Setup of entire operation including shifts for first month
- Import of employees and qualification matrix
- Training of production manager and supervisor
Automatic planning
Mobile solution
- Employees request overtime and enter sick leave and vacation directly in the app
- Manager solves substitutes in a minute from mobile, doesn't need to carry laptop on weekends and can handle everything efficiently
- End of calling and turning on computer
Achieved Results
Annual savings: 153,600 CZK
Management time savings:
- 32 hours weekly gained by production manager and supervisor
- 12,800 CZK monthly saved on administration (at 400 CZK/hour cost)
Staffing optimization:
- 11 additional shifts covered by existing employees monthly
- Elimination of need to constantly train new employees
- Optimal utilization of work capacity
Operational benefits:
- Problem-free coverage of all workstations without errors
- Simplified substitutability of production manager
- End of weekend calling employees
Key Benefits
No downtime
Automatic coverage of all workstations
Mobile flexibility
Solving substitutes in a minute from phone
Strategic management
Time for production analysis instead of administration
Easy substitutability
System works even without manager
Happy team
Transparent mobile application for employees
What the production manager says
Ready to automate your shift planning?
Manufacturing Plant
290 employees + 100 temporary workers - flexible staffing automation
The Challenge
Initial situation:
- Every Thursday and Friday the HR coordinator wrote out shifts and called temporary workers
- 16 hours weekly devoted to this administration
- Complicated operation coverage due to irregularity of temporary workers
- Variable demand and planned absences of full-time employees
Critical complications:
- Irregular part-time hours of temporary workers
- Weekly fluctuations in labor demand
- Manual calling of a hundred people every week
- Supervisors had to adjust production according to available capacity
Solution with Ai-Mistr
Self-service platform
- Temporary workers and contractors have access to the Ai-Mistr app
- Required unfilled workstation counts from production go into system
- Temporary workers submit shift requests themselves directly from app
Automatic verification and approval
- HR coordinator only approves requests instead of calling
- System automatically checks qualifications and hours worked
- Automatic work time reporting of employee work time
Flexible staffing
- Immediate response to demand changes
- Optimal utilization of available workforce
- Elimination of insufficient shift coverage
Achieved Results
Annual savings: 336,000 CZK + higher production efficiency
Dramatic HR time savings:
- 70 hours monthly saved for coordinator
- 28,000 CZK saved on administration (at 400 CZK/hour cost)
Operational benefits:
- 100% shift coverage – end of understaffing
- More efficient production – supervisors no longer need to adjust what to skip
- Automatic work time reporting odpracované doby
- Satisfied temporary workers – flexible shift selection
Key Benefits
Self-service system
Temporary workers choose shifts themselves
End of calling
Automatic coverage of up to 100 positions weekly
Full production coverage
No skipping due to lack of people
Automatic checks
Qualifications and hours without errors
Happier team
HR, supervisors, and temporary workers
Transformation of Weekly Cycle
Before Ai-Mistr:
Thursday: Writing shifts in Excel
Friday: Calling hundred temporary workers
Result: Often incomplete coverage, stress
After Ai-Mistr:
System: Automatic posting of production needs
Temporary workers: Choose suitable shifts themselves
HR: Only approves with automatic verification
Result: 100% coverage, peace of mind
Impact on the Entire Operation
Do you need to coordinate hundreds of flexible employees?
Printer
250 employees - mastering growth without chaos
The Challenge
Key problems:
- 10-20 daily substitutes requiring manual Excel management
- Dozens of hours monthly spent by supervisors on staffing changes
- Risky substitution – substitute supervisors didn't know qualifications of other teams
- Outdated qualification matrix blocking employee development
- Dispatchers overwhelmed with administration instead of handling orders
- Overload, substitute numbers, and lack of qualification knowledge caused planning errors leading to production downtime
Solution with Ai-Mistr
Quick implementation
- Setup of pilot operation including shifts for first month
- Import of employees and qualification matrix
- Training of dispatchers and supervisors
Automatic staffing
Intelligent optimization
- Immediate notification of conflicts during manual editing (even across teams)
- Optimal utilization of existing employee work capacity
- Mobile application for overtime and vacation requests
Achieved Results
Annual savings: 960,000 CZK
Management time savings:
- 200 hours monthly gained by dispatchers and supervisors
- 80,000 CZK monthly saved on administration (at 400 CZK/hour cost)
Staffing optimization:
- 1.5% more shifts covered by existing employees
- Savings equivalent to 4 additional employees
- 160,000 CZK saved on recruitment and training (40,000 CZK each)
Operational benefits:
- All workstations covered without errors leading to downtime
- Simplified substitutability of supervisors and dispatchers
- Substitution of unutilized employees across halls
- Maintaining current qualification matrix for employee development
Key Benefits
Error-free operation
Elimination of downtime through qualification checking and correct staffing
Growth scalability
Handling 150% employee growth without chaos, with same number of supervisors and coordinators
Expert work management
Dispatchers focus on orders instead of administration
Easy substitutability
Functions even during absence of key people
Continuous development
Current qualification matrix supports career growth
Transformation of Work Methods
Before Ai-Mistr:
Dispatchers spent large part of day handling 10-20 substitutes
Supervisors dozens of hours monthly on staffing changes
Chaos during management vacation and sick leave
After Ai-Mistr:
Automatic substitute handling in seconds
Supervisors focus on training and operation optimization
Smooth operation even during absence of key people
Do you have similar growth and need to manage complexity?
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