Factory planning & Realization

Design and Start-up of new production facilities or site expansions

With more than 30 years of consulting, we have a wealth of experience in factory planning for discrete manufacturing, plant and machinery engineering as well as in the process industry. Working with our clientswe develop and implement production and supply chain systems based on Operational Excellence Principles.

We use state-of-the-art lean management principles to plan and optimize production and manufacturing processes as well as logistics warehouses up to 40,000 m², not just in Europe, but also in Asia as well as in North America.

 

Layout and integration planning

 

Material Flow Management

 

Implementation support and Start-up

 

Relocation of Production Facilities

Your business model is the starting point for our engagement. We will work closely with you to define your own individual goals and to specify the requirements for all processes.

For the "greenfield process", the first step is for our consultants to take your specification sheet and transfer it into a clearly structured block and function layout that divides the areas. This is based on a value stream-oriented material flow. Working with 2D and 3D-CAD, allows us to align the planning status with your specialists and monitor progress against the project specification, no matter where they are worldwide.

Specific plants also have special requirements, which have to be provided by the building infrastructure.

Through our proven expertise across various industries, we will make sure the building infrastructure includes all requirements that your machines and equipment need.

Whether this is the standard media supply, the building management system, emission limits or the right fire safety concepts, our consultants will also be available to support you.

The efficient material flow management is a pre-requisite for the high cost effectiveness of the processes in your company.

When planning a factory, we make sure that the material flow is always aligned with the profitability of the internal material movements. In addition to the number of installed systems, their arrangement and interaction has a huge impact on the planning.

Whether the supply of raw materials, linked processes or the establishment of buffer storage, the resources must be moved, interference free and ‘just-In-time’.

In order to verify the plausibility of the planning and to detect bottlenecks at an early stage we work with simulation tools to imitate the process.

We look forward to getting to know the demands of your material flow.

The step from the digital planning environment to the physical implementation on the construction site is not only exciting, but sometimes also very challenging. As an interface and main contact for all construction-relevant questions between you as the client and the contractors, we will coordinate all resulting tasks.

We not only accompany the construction of the building structure, but also the integration of devices, as well as the commissioning and handing-overof all equipment from the machines to the workstations - whether in a new facility or site expansion.

Whilst plant technology can be integrated based on a set of parameters, your new and current employees must be prepared for the challenges ahead. We will compliment your transformation process with tailor-made training courses, as well as specialist and management development programs.

Not all factory investments are ‘green fields. The relocation of existing production sites can be a complicated process with very special challenges.  Rarely, can the production be stopped completely and the production subsequently moved.

Although the process appears to be completely different, the classic factory planning tools are also used here. The unique opportunity to restructure existing processes requires a detailed analysis of existing optimization potentials, or the revision of the business model targets and criteria. This often results in a new design and area layout with revised process linking and increased automatization.

The key learnings from an existing material flow are transferred to the new process, as well as the previous integrations plan and inauguration of the site.

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