Auto makers have stringent demands of OEM manufacturers for on-time delivery and inventory requirements. Bumper modules must be delivered to the car manufacturer "just-in-sequence” and are usually produced to order. The processes for plastic injection and painting follow completely different rules, but must still be scheduled optimally, in tact with the just-in-sequence delivery date.
In bumper manufacturing, it is necessary to account for the combinations of different molds, tools and inserts, raw material, and even labor. It becomes exponentially hard to plan with a visibility of all these requirements, and the larger the backlog, the more challenging it becomes to consider all these constraints.