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Intelligent Production Planning with PrimaV® OPAL V10 forWPA and Processing

Connected. Automated. Optimized.

The Multi-Site PrimaV® OPAL Production Planning System V10 stands out for its intelligent planning, optimal capacity utilization, maximum flexibility, and exceptional usability—tailored to your specific needs in WPA and further processing.


PLANNING WITH CONFIDENCE.

In Focus: Optimizing Your Production

Why PrimaV® OPAL V10?

  • Integrated decision support: Interactive dashboards and KPI monitoring provide transparency regarding critical situations; what-if simulations check production schedules for bottlenecks and areas requiring action.
  • Transparent Capacity Management: Intelligent Capacity Management optimizes the utilization of machinery, personnel, and resources and leverages synergies in a targeted manner.
  • Automated Planning Recommendations: Smart Planning automates routine planning and shifts the focus to efficient exception management.
  • Configurable planning logic: Flexible rules engines take into account specific plant, machine, material, and customer requirements.
  • Flexible Adaptation: Production schedules can be dynamically adjusted—enabling a quick response to last-minute orders, changes in capacity, or disruptions.
PrimaV® Opal Web and Navigator

A Complete Plan in Just a Few Clicks

  • Set Basic Data: Define the program's name, time period, and scheduling script.
  • Generate Schedule Automatically: Distributes the production sequences to the selected machines with a single click.
  • Key Metrics at a Glance: Assigned production sequences, rejected BTAs, capacity utilization, and planning windows at a glance.
  • Gantt Preview: Displays machine utilization over time, including periods when the machine is unavailable.
  • PrimaV OPAL Navigator: the planning simulator—simulation of warehouse layout, display of inventory and fill levels as percentages, and a planning board with time simulation.

Perfect when used with PrimaV® ERP

PrimaV® Packaging. Networked. Automated. Optimized.

About PrimaV® Packaging ERP
PrimaV® PPS Modules

Production planning

Controlled processes = corporate transparency

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Capacity Overview

Keep an Eye on Production Capacity at All Times

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Optimization of Cut List

Calculating the Optimal Usable Width for WPA and Further Processing

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Production Control Centre

The interface between the purchasing department, suppliers and production

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Production Data Acquisition BDE

Analyse time, labour and materials used

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Controlling

The post-calculation of all your business processes

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Analytics

Configure key data for better company management

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PrimaV® ERP – Additional Modules and Options

Quality management

A controlled increase in product quality

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Customer Relationship Management (CRM)

Find customers – keep customers

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Workflow & Organiser

The path to a truly paperless office

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PrimaV® Mobile

The app for field service management

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PrimaV® Web

Stay globally connection with the ERP system

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EDI Electronic Data Interchange

Automate data exchange

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PrimaV® Production planning

With optimised planning and structuring of workflow, you can create the ideal conditions for a smooth production run. The production planning module offers the perfect functions for you to check material availability, as well as make material requests for both order-neutral and order-related items.

 

You can directly make orders or calls for contract quantities, and the material flow is also supported via an extended workbench. You can also create a capacity plan based on cost centres or machines.

Functions

    • Scheduling
    • Existing materials
    • Tools
    • Cliches

      Selection of orders to be produced based on various criteria:

    • Creation of work files with CAD drawing (with CAD connection)

  • Customisable pallet slips with barcodes

  • Production notifications with stock entry

  • Production order

  • Process control

PrimaV® Capacity Overview

The capacity overview lets you keep track of your production utilization at all times. A clear heat map shows the utilization of all machines in either a daily or weekly view. This makes bottlenecks and available capacity immediately apparent, allowing you to respond early. When you select a machine or a combination of time period and machine, the associated operations appear in a detailed table. The system distinguishes between planned and unplanned orders. Bottlenecks can be resolved directly in the overview. You can reschedule operations to other machines and immediately adjust production, shipping, and delivery dates. Additionally, the system checks whether tools or printing plates are also used in other orders. Tools and printing plates used in multiple orders are highlighted in bold. A tooltip shows you exactly which order is involved and when it is running. This allows you to bundle orders early on and take advantage of synergies in subsequent detailed planning—for example, by reducing the number of setup operations.

Features

  • Graphical representation of machine utilization as a heat map with daily and weekly views
  • Color-coded indication of utilization, bottlenecks, and available capacity
  • Detailed view of production steps by:
    • Machine
    • Machine and time period
  • Tabular overview with additional order and production step information
  • Rescheduling of production steps to other machines
  • Direct adjustment of deadlines
  • Automatic check for multiple use of tools and printing plates
  • Highlighting of tools and printing plates used multiple times with a tooltip showing the job and date
  • Early identification of synergies for detailed planning
  • Support for capacity checks and production

PrimaV® OPAL Optimization of Cut Lists

With cut list optimization, you can make optimal use of your corrugator’s working width and reduce edge trimmings. Optimization can be performed either manually or fully automatically. The planner retains full control over the result at all times.

In manual optimization, the planner selects the desired jobs themselves. The software then determines the possible combinations based on the available widths, and the planner chooses the appropriate solution. This solution is saved and can be scheduled later in the control center.

In automatic optimization, the program handles both the selection of jobs and the choice of the best optimization result. This is based on predefined criteria for the individual steps. If no optimal solution is found, the planner can choose from the suboptimal results or escalate the product types automatically or manually. The program’s selection can be reviewed and modified at any time. If the result is acceptable, the solutions are saved and scheduled in the control center or automatically scheduled directly, including further processing.

Translated with DeepL.com (free version)

Features

  •  

Manual cutting list optimization

    • Manual selection of jobs
    • Identification of possible combinations based on available widths
    • Selection of the desired combination by the planner
  • Automatic cutting list optimization
    • Automatic selection of jobs
    • Automatic determination of the best optimization result
    • Freely definable criteria for the individual optimization steps
  • Display and selection of suboptimal solutions
  • Escalation options
    • Automatic
    • Manual
  • Review and adjustment of the selection made by the program
  • Saving the optimization results
  • Transfer to the control center
    • Manual scheduling
    • Automatic scheduling, including further processing

Production / process control centre

Controlled guidance of your production processes

Production control enables detailed control of all your processes, from machine planning to production notification, all the way to product completion. This module offers Gantt charts or a numerical production control station, capacity management, individual process management and alternative resource groups. With the Production Planning module of PrimaV®, you can gain complete transparency and control of your production processes.

The PrimaV® Process control centre has been redesigned and now offers a variety of new options that make production even easier and more transparent. As well as technical improvements in speed and handling, the new control centre can, amongst other things, use frozen zones to schedule production orders semi-automatically. The control centre can also create overlapping orders, with even more precisely calculated scheduling.

Functions

  • Graphic planning board, planning optimisation
  • Selection of orders to be produced based on various criteria
  • Production notifications / production orders
  • Graphic process control station with Gantt chart
  • Numerical process control centre (displayed with day/week overview)
  • Frozen-zones for semi-automatic scheduling
  • Capacity planning
  • Machine/Cutting die/cliche management
  • End-to-end serial number/batch tracking
  • Display of the current production status on tablet/smartphone
  • Overlapping manufacturing sequences
  • JDF/JMF compliance (Heidelberger printing machines)

Operational/machine data acquisition

Reduce costs through transparent manufacturing processes

The PrimaV® Production/machine data acquisition BDE and MDE module registers and analyses the time, work and material expenditure for your production processes. Based on these results, costs are automatically calculated.
All production data is collected immediately and in real time, and is available for the current production processes. Malfunctions and delays are signalled immediately so that appropriate countermeasures can be taken. Extensive and flexible evaluation tools enable continuous product and process control.
By recording all data around your product development, the software supports you with all process documentation and later tracing and evaluation processes.

Functions

  • Simple data collection via touch screen
  • Login via RFID chip and reader or PIN entry via touchscreen
  • Face recognition by camera
    Management of multiple machines per terminal
  • Automatic bookings
  • Viewing PDF documents
  • Videojet compatible
  • PLC compatible (programmable logic controller)
  • Interface to PrimaV® staff time-tracking
  • Masks can be configured according to customer requirements

PrimaV® Post calculations

The aim of post-calculations is to determine and control the costs of orders that have already been processed and to calculate the actual data and profit made. By comparing target specifications from the pre-calculation and the actual data, the pre-calculation can be checked, and the result can be used to carry out future pre-calculations. Deviations are identified and can be taken into account in future pre-calculations. This optimises sustainably controls manufacturing processes and costs. Contribution margin 1 and Contribution margin 2 are available as key figures.

Functions

  • Master data management (customers/suppliers/items/conditions)
  • Order management with process history
  • Integrated communication solution possible
  • Manual collective delivery notes/invoices
  • Processing of framework agreements
  • Electronic invoicing
  • Commission statements
  • Complaint management
  • Accounts Receivable/Accounts Payable
  • Open item management with dunning
  • Batch traceability (material, article)
  • Comprehensive statistics
  • Numerous filter and search criteria
  • Comparison of target quantities with yield from the BDE and reported yield
  • Comparison of material consumption (incoming, hazards, waste)
  • Inclusion of special costs
  • Production and concurrent final costing

PrimaV® Analytics

Make company decisions based on real data – build a solid foundation of comprehensive, reliable and meaningful key figures.

With PrimaV® Analytics, you can individually compile, evaluate and present statistics and evaluations that are company-specific and always up to date.

Whether its incoming orders, item data, sales figures, cost centres or other important key figures – your data is displayed clearly in numerical or graph form on your dashboard, showing you the most important data at a glance, in your desired form. Customised for your individual company, profit centre-related or cross-production site.

The perfect foundation to build your business decisions on…

PrimaV® Quality management

There’s nothing that can’t be made better...

Due to the globalisation and internationalisation of markets, companies have to continuously adapt the quality of their products and services to the needs of their customers so they can stay competitive.
The PrimaV® Quality management module supports your processes from the delivery of the raw materials, all the way to the moment when the end-product leaves the factory. The module is all about sustainable optimisation in the procurement, processing and control of your materials. With the PrimaV® Quality management module, you can achieve a continuous and significant improvement of your products.

Control your processes

From the delivery of raw materials to the finished product

Receipt of goods:

  • Incoming material inspection
 

Process planning:

  • Material release request
 

Production data acquisition:

  • Defined sampling procedure in the production process of printing/punching
  • Creation of sheet control certificate
 

Quality assurance of finished goods:

  • Approval of yield / rejects
  • Creation of the final inspection certificate

CRM Customer Relationship Management

Customer relationships in focus

The PrimaV® CRM for the packaging industry seamlessly connects customer relationship management, sales, and project-related information with the PrimaV® ERP system. Customers, prospects, contacts, processes, documents, and files are managed centrally, providing sales and order processing teams with a shared, up-to-date source of information.

At the heart of the solution is the PrimaV® process, which serves as a digital project file. All information relating to a customer order or project – from business documents and email correspondence to drawings, images, and other files – can be assigned to a process and brought together in one central location. This gives all departments involved quick access to the information they need, helping workflows move forward efficiently without unnecessary internal enquiries.

The Microsoft Outlook Integration for PrimaV® connects everyday email communication directly with the CRM and ERP system. Emails can be assigned to processes and documents, while appointments and calendars continue to be managed centrally in Microsoft Outlook. In this way, PrimaV® brings together customer and project information from the ERP system with day-to-day communication and scheduling in Outlook – creating a connected, transparent workflow across the entire customer journey.

PrimaV® CRM – Functions:

  • Customer and contact management: Centrally manage customers, prospects, contacts, and contact details.
  • Digital project file: Bring together emails, business documents, drawings, images, and other project-related information within PrimaV® processes.
  • Process management: Structure and track customer orders, projects, and all related activities in one place.
  • Document management: Centrally assign, organize, and access customer- and project-related documents.
  • Sales activity planning: Plan and track sales activities and customer interactions efficiently.
  • Microsoft Outlook Integration: Link emails to processes and documents in PrimaV® while managing appointments centrally through the Outlook calendar.
  • Filters and selections: Analyze and segment customer, contact, and process data using targeted filters and selection criteria.
  • CTI integration: Connect telephony with customer information through Computer Telephony Integration (CTI) for more efficient communication.

Workflow & Organizer

Intranet and seamless communication – The path to a truly paperless office

PrimaV® Workflow

Your customer calls – you interactively create a basic info sheet for the requested product using your checklist – or…

You receive an e-mail – it automatically gets labelled as an enquiry email and product data is added to it, using the checklist.

The completed checklist is then electronically forwarded, along with all the information needed.

The benefits: You don’t have to work with texts, but with useful information that can be directly processed. The information is stored in a structured and ordered system. All processes are handled in a clear and transparent way. Inter-departmental communication is solely electronic – say goodbye to handwritten notes or misunderstood texts. No more misunderstandings due to awkward games of telephone. All the order and process status information is at hand for your authorised team members.

PrimaV® Organizer

The PrimaV® Organiser is an integrated communication module, with Outlook functionality. It allows your staff to communicate electronically via your company’s intranet, while also offering seamless communication with external partners (customers, suppliers, etc.) through the direct dispatch (e-mail or fax) of documents such as offers, order confirmations or invoices from the ERP system. You can display e-mail addresses and store templates. Find all your customer or process data in one place, perfectly summarised, alongside attachments and follow up reminders. Your staff can view enquiries, orders and processes whenever needed, add additional info, and process them further.

PrimaV® Schedule

With the help of PrimaV® Schedule, you can have a clear overview of all business appointments, and even staff absences. Invite meeting participants, set reminders or store appointment processes. An interface with PrimaV Time Tracking data enables you to automatically transfer data on absences due to holiday, sick days, etc. from the time tracking sheets. Numerous filter and authorisation settings ensure tailored setup options for individual employees or departments.

PrimaV® mobil

Apps for management and field service

Ideal working for the 21st century: Link your mobile devices to the stationary ERP system. All the important data, information and appointments are available to your managers, employees and field staff – worldwide, promptly and always up to date.

Features

PrimaV® iSales – The mobile sales module:

Display, capture and process all data relevant to sales, such as

  • Master data (customer and supplier)
  • Contacts and visitor reports


Connection / synching on mobile devices:

Displays of current production status on smartphone/tablet (machine, operational order number, item, machine status, actual quantity)

View and edit via smartphone:

Contacts

Appointments

Emails

 

Displays of

  • Receipts and customer activities
  • Sales divided by customers, item groups or items
  • 3-year comparisons of customer sales 

Integration of a business scheduler for you and your team

Interface to PrimaV® Web Calculation

Web solutions

Global connections with the ERP system

With the PrimaV® Web solutions you can access information worldwide: Expand your business reach with web-based services, achieve shorter processing times and thereby reduce your costs. Everything benefits from this – your staff in the office and in the field, as well as your customers.

Improve cooperation with your business partners by providing them with a convenient web platform. Your customers can independently calculate item prices, find out about the status of their orders, determine availability, request quotes or place orders. This takes the load off your team while offering your customers a comprehensive service.

Features

Functions of the PrimaV Web calculation

  • Quick entry of the calculation in PrimaV®
  • Direct creation of customer quotes/orders
  • Data transfer to the PrimaV production system in real time
  • Quick and easy circulation price determination for the web user
  • Display/download as a PDF document and email delivery

Functions of the PrimaV Web shop

  • Display of framework agreements and direct order retrieval 
  • Article display, including stock levels
  • Display of the current order status
  • Quote creation can be made directly by the customer online

EDI - Electronic Data Interchange

Fully automated data exchange

PrimaV® EDI makes it possible to convert business data (such as orders, delivery notes, invoices) from your own ERP system into structured and standardized data and send it electronically, in just a few seconds.

This gives you a great potential for rationalization in your business transactions. With EDI, you can significantly reduce the manual effort required, while increasing data quality.

EDI can give you competitive advantages over those not using it. It improves your company’s organisation and simplifies and intensifies business relationships with partner firms (suppliers, customers, freight forwarders, banks, etc.). In this way, you can prove your quality and skills to your partners competence, for example with just-in-time deliveries.

Prerequisites for using EDI are standardised data formats for messages and uniform communication channels for their transmission. To achieve this, both business partners need EDI software. Our partner is Softzoll GmbH & Co. KG in Berlin.

PrimaV® supports the following message types:

Orders (commissioned by customer)

ORDRSP (order confirmation to customer)

Desadv (Delivery Advice Message)

Invoice