Production planning 

A holistic view of production for more efficiency.

Manufacturing: the heart of the company 

Automation and digitization

Due to strong competition, especially from low-wage countries, production in high-wage locations like Germany is under increasing cost pressure. To remain competitive and expand advantages, modernization and optimization measures are necessary. This challenge succeeds through automation, digitization and concentration on your own core competencies.

However, while maintaining the location in the high-wage country is a challenge, there are also many other reasons that call for rescheduling or re-planning of your production. Growing sales figures lead to bottlenecks in machine capacities, while small batch sizes lead to increased set-up times. This runs counter to the goal of efficient production with reduced throughput times. 
 
Changes in the product range are also noticeable in production. In order to equip production for the future, adaptability and flexibility are important aspects. 

Thanks to the change in the market towards shorter product life cycles and more varied products, with increased cost pressure and quality requirements, the challenges of the future-oriented planning task, which forms the basis for a successful and sustainable achievement of your corporate goals, increase.

We’ll support you in production planning

  • Planning of a production concept that meets the requirements
  • Material flow optimization and layout planning for production
  • Examination of automation aspects
  • Creation of a technology roadmap
  • Capacity planning with growth plan
  • Invitation to tender and start-up support
  • Cost-benefit assessment of investments
Manufacturing concept

The right concept for your production

Within the scope of the production strategy, there are different concepts to adapt your production to the general conditions of your company.

The degree of automation, the required flexibility and the prevailing variety of variants are examples that have an influence on the chosen concept. 

Whether product-oriented flow production, process-oriented series production, function-oriented workshop production, value stream-oriented island production or a mixed form turns out to be the optimal solution for you, we will be happy to help you adapt and optimize your production to the circumstances!

 


Material flow optimization and layout planning for production

A value stream optimized layout increases effectiveness

Many companies notice historically grown, highly fragmented structures in production that may have started with a value stream orientation at the beginning. However, creeping changes over the years often lead to confusing and inefficient material flows.

A new or rescheduling of the production offers the possibility of rethinking the grown structures and making the production more efficient and transparent through a value stream optimized layout. We are at your side with our many years of experience in layout planning.


Testing of automation aspects

Using automation for efficient production

Digitization leads to added value in the automation of production with positive effects on efficiency and quality.

In modern production, in addition to the automation of the manufacturing processes in machining centres with automated tool changes, the linking of the machines and thus the handling of the workpieces are controlled and carried out by machines.

AGVs, robots or intelligently controlled transport systems optimize the supply of the processing machines. In terms of Industry 4.0, the sensor system detects changes in the key figures of the machines at an early stage and can thus initiate maintenance measures before a drop in quality.


Creation of a technology roadmap

The way to your future-proof production

A realignment of production to become more modern or to specialize in its core competencies requires good planning of the target state and the implementation. 


We start with an analysis of your current technology portfolio in order to develop the potential for change or optimization.

Working closely with you, we develop possible technologies for your production, create profiles and evaluate the different technologies.

In this step, the need for modernization in the machine park is determined, and innovations are examined.
After planning the target state, it is vital to prioritize the technology projects and define development stages for the necessary technology investments.

 

Various growth scenarios can also be planned in the technology roadmap in order to strategically equip your production for the future.


Capacity planning with growth plan

Optimization of the capacity utilization

The volatility and dynamics of the market represent a challenge for capacity planning in production. Based on volume forecasts and growth scenarios, we determine the required machine capacity for the future and work with you to work out ways of eliminating the bottlenecks economically. 

Whether through multi-shift operation, purchasing new machines or investing in new technologies, you will find the right solution together with our expertise.


Invitation to tender and start-up support

From planning to deployment

Even after the planning stage, we are still there for you! There are technology projects planned, but you currently have no capacities, or you lack the necessary know-how for the tender and subsequent review of the concepts?

We help with the invitation to tender, with the definition of the specifications, the creation of specifications and elaboration of the technical requirements up to the technical-economic comparison of the offers, the definition of the acceptance conditions and support the start-up of the new production.


Process simulation and process display

Validation of planning through simulation

After the production planning has been completed, we offer the possibility to check the neuralgic points of the production by means of a dynamic process simulation.

The dimensioning of the bottleneck can be safeguarded; the machine utilization, throughput times, buffer sizes, personnel resources and the dynamic allocation of storage locations are examples of verifiable key figures.

We compare different scenarios and explain the improvements in material flow compared to the current situation. 


Smart Factory Parsdorf

ein Jahrhundertprojekt

Referenz

ifp consulting begleitete KraussMaffei bei der größten Standortverlegung in Bayern seit dem Münchener Flughafen “Franz Josef Strauss”.


KraussMaffei ist einer der weltweit führenden Hersteller von Maschinen und Anlagen für die Produktion und Verarbeitung von Kunststoff und Gummi. Das Branchenportfolio reicht von der Automobil-, Verpackungs-, Medizin- und Bauindustrie bis zu Herstellern von Elektrik- und Elektronikprodukten und Haushaltsgeräten.

Im Januar 2020 begann ifp consulting, die Realisierung des neuen Standorts mit planerischer und organisatorischer Expertise zu unterstützen. René Dierkes, Gesamtprojektleiter Werksneubau Parsdorf, KraussMaffei Technologies GmbH: “Die Zusammenarbeit war von Anfang an ebenso angenehm wie effektiv. Besonders förderlich für das voranschreiten des Projekts ist die klare systematische und analytische Vorgehensweise des ifp consulting Teams. Darüber hinaus leistet auch die kommunikative Kompetenz in den einzelnen Abstimmungsprozessen einen entscheidenden Beitrag zur fristgerechten Erarbeitung und Umsetzung von Lösungskonzepten”.

Zur Förderung zukünftiger, technischer Neuerungen wurde auf die folgenden Aspekte besonders Wert gelegt:

  • Werkslogistik mit hohem Automatisierungsgrad
  • Optimierte Prozesse
  • Konsequente Digitalisierung
  • Nachhaltigkeit & Energieeffizienz

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