Factory concepts and rough planning

We’ll develop the basic concept together with you.

Concept planning

Factory planning for all industries

Often, at the beginning of a planning project, there are initial ideas of what the future factory or redesign of the existing production facility should look like. Creativity knows no limits. But there is a wide range between creative design approaches and functioning factory planning.

Concept planning serves to work out different factory structure variants and to compare them with one another. The main focus is on:

Development of target processes (value stream design)
Development of an ideal function diagram
Selection of the appropriate production concept
(Workshop production vs island production vs line production)
Construction and dimensioning of various real factory structure variants
Creative block layout development with digital support from an innovative touch planning table
Material flow simulation with the latest digital tools
Structured and transparent evaluation of the variants based on quantitative and qualitative criteria

We’ll accompany you in the structured development of your factory concept and guide you through the process to a factory that meets the diverse requirements.

Optimal factory concept

Development of the optimal factory concept

The development of basic factory concepts and the visualization initially on the block layout level are the core of this phase. These variants are created based on the defined target processes and the dimensioning of all relevant areas.

In preparation, automation concepts for assembly and logistics (e.g. AutoStore, shuttle warehouse, assembly robots, human-robot collaboration) are checked for customer-specific suitability. The development of possible plant structure variants considers all building, production, process and quality-related restrictions, and future requirements. In the next step, these variants are compared with the help of a technical and economic benefit analysis. For this, quantitative and qualitative evaluation criteria are taken into account. By evaluating the comparison of variants, the optimal plant concept on the block layout level as well as the future flow of rough goods are determined.

We’ll support you with the rough planning  

Manufacturing concept
Assembly concept
Layout planning
Logistics planning
Warehouse planning
Intralogistics planning

Consumer goods industry customer example

Reference

Consumer goods industry

A plant structure planning was carried out for a German family company and representative of all-encompassing sleeping comfort.

Project goal

The focus was on creating a plant structure and logistics concept with cycle line planning.

Implementation

Based on the optimization potential, various plant structure variants were developed and evaluated. After the selection, the detailed planning of the plant concept followed, followed by implementation planning.  

ifp’s approach

With the help of a process analysis, optimization potentials in product segmentation, production control and inventory were determined.

Result

As part of the factory structure concept, integrated production control using an ERP system and warehouse space optimization led to a significant reduction in inventory.

Automotive industry customer example

Reference

Automotive industry

We carried out a plant structure and assembly planning for a German manufacturer of trailers, bodies and semitrailers.

Project goal

The focus was on the development of a plant structure and assembly concept.

Implementation

75% of the products were integrated into a timed volume line in the form of a U-layout.

ifp’s approach

On the basis of a comprehensive data and process analysis, the product portfolio was segmented and the volume assemblies were clocked.

Results

In order to increase efficiency, the segmentation of various products in a timed volume line and a stand assembly of the exotic products were introduced.

Plant structure concept customer example

Reference

Paint and finishing industry

ifp consulting created a sustainable plant structure concept for a customer in the paint and finishing industry.

Project goal

The main idea of the project was the development of a modern and efficient plant structure for all production and logistics areas that can be implemented sustainably. 

Implementation

A plant structure concept was developed and introduced.

ifp’s approach

The project was divided into the following phases: 

  • Process and data analysis
  • Identification of potential
  • Creation of an ideal layout
  • Variant development and evaluation

Results

The result was an increase in production capacity with a small increase in area and thus optimized construction costs.

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