Plant structure planning
Humbaur

Plant structure 2030

How did we help?

Our client, Humbaur GmbH, is one of the leading trailer manufacturers in Europe and produces around 60,000 trailers per year at its Gersthofen site near Augsburg. We were able to further develop the plant concept in Gersthofen for Humbaur GmbH and align it with future requirements as well as identify potential savings through the introduction of new technologies, optimized material flows and automated warehouse solutions.

The task:

Sustainable further development of the existing and historically grown plant concept at the Gersthofen site.

The project:

Humbaur GmbH is planning a comprehensive modernization and expansion of the plant structure at the Gersthofen site in order to enable long-term and sustainable growth. The aim is to develop a holistic plant concept that takes into account the current framework conditions, new product structures and increasing quantities. Together with ifp consulting, various layout variants were developed that optimally align assembly, logistics and production for the future.

ifpconsulting plant structure planning and brownfield planning clientvoice and use-case Humbaur by Olaf Sackers, Managing Director Humbaur GmbH "With the support of ifp consulting, we were able to further develop our plant concept in Gersthofen in a targeted manner and align it with future requirements."

What have we achieved?

In the focus: key figures and results

Reduction in logistics space with increasing quantities

ROI within the target period

Higher degree of space utilization through mixed model lines

Ask our experts

Ask our experts

Customer testimonial Humbaur

Olaf Sackers

Executive Director Humbaur GmbH

“With the support of ifp consulting, we were able to further develop our plant concept in Gersthofen in a targeted manner and align it with future requirements. The structured analysis and the jointly developed layout variants have created transparency, leveraged potential and given us a clear roadmap for future investments.”

Our contribution

Problem

The Gersthofen site is characterized by historically grown structures. The distribution of space and the capacity utilization of assembly no longer meet the requirements of the planned growth. There is a need for optimization in terms of space efficiency, assembly segmentation and process transparency.

Challenges

The project work required dealing with a limited and partly heterogeneous data basis, the quality of which had to be ensured for reliable analyses. The ambitious schedule was met thanks to the extraordinary team effort and quick decision-making by the management. The development of complex scenarios regarding the expansion stages of the production processes at the site and their impact on the layout requirements was particularly challenging. The scenarios also had to be translated into well-founded ROI calculations in order to make investment decisions transparent and comprehensible.

The collection of palletization data and carton quantities posed a particular challenge, as these were not visible in SAP MM. This information was recorded and carefully validated as part of the inventory analysis and warehouse dimensioning. This created a solid data basis that made it possible to design the warehouse to meet demand in 2035.

Approach and methodology

In several sprints, the basic principles were updated, space requirements determined and various layout variants developed. The methodology included:

  • Analysis of the current plant structure and space distribution

  • Definition of different specification variants for the production processes and their effect on the layout variants

  • Scaling of assembly, logistics and production areas based on new growth figures

  • Development of mixed model lines to increase flexibility and space efficiency in assembly

  • Evaluation of the layout variants with regard to material flow, expansion options, implementation costs and risk

  • Carrying out ROI analyses for all production processes and layouts

  • Joint workshops to select the favorites and create a roadmap for implementation

The solution

The favoured option envisages the expansion and modernization of the existing assembly, logistics and production halls. The potential savings from the introduction of new technologies, optimized material flows and automated warehouse solutions were determined. The investments in buildings, machinery and equipment will be amortized within the target period. The new plant structure enables flexibility and forms the basis for further growth and digitalization.

Cooperation and outlook

Efficient processes and growth opportunities

The next steps are to decide on a plant concept, plan the manufacturing processes in detail and implement the roadmap.

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How we can optimize your processes

Our team of seasoned professionals brings decades of experience in production and logistics optimization. By partnering with ifp consulting, you gain access to industry-leading insights, methods, tools and technologies that deliver immediate and tangible improvements. Contact us now to make the transformation and optimization of your processes a success!