Process and factory planning efficient and highly focussed
Without detailed planning, investment in new processes or factories will quickly become a waste of money. Here you should leave nothing to chance, but rather trust in professional consultancy. ifp consulting has the skills, the experience and the methods for efficient, highly focussed planning.
With our "digital factory" we are able to show you now how you can make your investment pay in future.
Master planning and Factory planning
Master planning and Factory planning par excellence
Regardless of whether you are building a new factory or want to renovate your existing factory, we will assist you at every stage of planning – from definition of objectives through to a concept worked out in detail.
Consistent and sustainable master plan and work structure plan Design of efficient production and assembly processes Optimisation of material flows and in-house logistics processes Innovative concepts for machines, systems, warehousing and materials handling technology Layout optimised to suit material-flow Simulation-supported optimisation of process sequences Digital factory planning
We do planning of factories always based on our basic principle of 3 A's:
AGILE, ADAPTIVE and ANTIZIPATIVE!
Process optimisation & Restructuring
Process optimisation & Restructuring
Constant growth, new products, new technologies and changed markets may make restructuring necessary. Ideally, ifp consulting should be brought on board at an early stage. Our experts know from experience how to remodel a factory in the most efficient and practical way, and will provide you with comprehensive assistance in optimisation, planning and implementation.
We support you during the planning of extension concepts based on current buildings, calculations green-field versus restructuring, validation of rebuilding costs as well as systematically process mapping and optimisation in all company divisions.
Warehouse and logistics planning
Warehouse & logistics planning
Crucial groundwork decisions are made in warehouse and logistics planning. Because it is associated with high levels of investment and complex functions, planning should be well in advance and supported by all the information needed for making the right decision. We will help you to develop the optimum technical and most practical economic solution – to enable you to face even major future market changes without major reorganisation work on your part.
We support you during following task:
Concept planning of warehouse- und logistics areas, distribution centers De- or centralisation of warehouse areas Development of stock level models for optimised stock levels Detailed analysis for the best level of automatisation Technical specification of automated high bay storage areas Definition and planning of manually and automated guided vehicles Planning of tugger train systems Selection and call for bids for storage equipment
Production and assembly planning
Production and assembly planning
Good planning forms the basis for successful implementation and sustainable achievement of corporate objectives. This also applies, of course, to production and assembly planning. Using innovative methods we will show you how you can achieve high levels of flexibility, increased production quality and reduced exposure to production and assembly.
We support you in regards of:
Overall concept planning of new assembly and production areas Segmentation concepts Analysis of optimised lot sizes Buffer calculations Equipment specification Concept of synchronized assembly lines
With a lean factory layout, every second is put to the best possible use. The expert consultants at ifp will help you to make your material flows transparent and shorten throughput times. Using powerful digital tools, we first analyse your current material movements. Then we can start systematically optimising material flow.
The result is maximum efficiency and measurable success.
Shaping tomorrow's processes with digital simulation studies
Using simulations, we are able to test and evaluate various processes. Potential bottlenecks are eliminated at the planning stage and opportunities are fully exploited. Our digital factory simulations are so close to reality that you will be able to follow processes in detail and thereby implement them quickly and efficiently.
With the help of the simulation tool we can find out following results:
Detailled capacity calculation Optimised lot sizes Optimised stock- and buffer size calculation Calculation of throughput times Production control concepts Optimisation of setup times Optimised number of labors Calculation of factory areas Calculation of maximum volumes
We have extensive long-term experience in calls for tender and tender preparation. Take advantage of our tried and tested repertoire of methods. With our help, preparing comprehensive tender documentation and organising the selection of potential partners will become child’s play.
Technical - Due diligence
Technical due diligence
Are you considering purchasing a factory or a manufacturing network? Do you need a detailed technical status evaluation report before reaching a decision? We are the right people to help you: In the context of a technical due diligence, ifp consulting undertakes a comprehensive, standardised and efficient analysis of the property concerned.
We will discover the answers to all the important questions that have to be assessed neutrally and expertly before the purchase of any property.
What production capacity can be expected?
What is the technical condition of the systems and machines?
Where can automation concepts be applied in future?
What level of quality will be achieved?
Could production be expanded?
We turn projects into practice on site at your premises!
Building new factories, reducing production costs, carrying out optimisation measures or relocating production in its entirety – experienced employees make their plans on the shop floor, on time and on budget. Skilful project management supports this as well as appropriate tools and methods, but also the necessary measure of pragmatism and systematic determination to transform a concept into reality. Throughout this process, we ensure technical application, negotiation and acceptance by the various professions, and adherence to specific schedules, control of resources and the processing of “outstanding issues” in the project as a whole.
We will support you in the start-up of factories, warehouses and production areas or with the launch of new products. Our highly experienced employees will plan the start-up in advance and reduce typical risks in a ramp-up phase. In the launch phase itself, staff will work around the clock to ensure that operations are scaled up smoothly, and optimise production or logistics as quickly as possible.
In a consistent production system, the industrial production subsystems – from production planning through to dispatch of the products – are perfectly synchronised. We will provide you with comprehensive support in regards of development and realisation of modern production systems with the targets: reduction of costs, increased productivity and improved competitiveness.
We offer comprehensive optimisation programmes for your business, with all processes aligned to client needs, quality and efficiency focussing on rapid solutions to the causes of problems. To the forefront is a perfectly-coordinated interplay of quality management, lean management, process management, leadership prioritising leadership excellence, teamwork, multi project and improvement management, communication and motivation.
With our experience and professional methods, we can support you on your journey to operations excellence!
We will help you devise optimisation strategies for production planning and control. With the help of special control strategies, we synchronize and streamline your production processes. Where needed, we create customised software tools to communicate directly with your existing systems.
System availability / Shop floor management
System availability/Shop floor management
Shop floor management is the precondition for the implementation of lean processes. In the first phase, we analyse the initial situation and future challenges for your machine pool. In a second phase, it is subjected to an extensive weaknesses analysis. Using appropriate key performance indicators and a detailed OEE analysis, we ensure transparent system availability. Using suitable methods (e.g. TPM, SMED, etc.), we can increase the availability of your machines based on a realisation planning.