How were we able to help develop a sustainable plant structure concept?
The initial situation:
Our client, VBM Medizintechnik GmbH, is a medium-sized company and manufacturer of medical technology solutions for airway management, accessories for anesthesia & intensive care and tourniquet systems. We were able to develop a clear target image and a sustainable plant structure concept for VBM Medizintechnik up to 2035 with efficient material flows and a clean room.
The task:
Due to the increasing demand for the products on offer, the adjustment of the strategic depth of added value and the need to renew the cleanroom technology, the company requires an optimized plant structure concept for the existing building structure. Particular attention was also paid to the current utilization of storage and logistics capacities and the inefficient flow of materials over several floors.
The project:
The aim of the project was to develop a sustainable plant structure concept for 2035. This included the analysis of material flows, assembly and logistics processes, the development of a clean room concept and a resulting future plant concept.
What have we achieved?
In the focus: key figures and results
Customer testimonial VBM Medizintechnik
Our contribution: How was the new plant structure concept developed?
Problem
The analysis of the material flow, the warehouse and inventory data, as well as the future capacity requirements in 2035 showed optimization potential in the logistics and production areas. These analyses also showed the limited capacity for growth due to the existing building structure.
Challenges
Due to the low building height, the challenges lie in the usability for storage areas and clean rooms, among other things. The existing building structure also restricted the ability to expand the existing cleanrooms.
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
The project was carried out in 7 sprints. The first step was to analyze the material flows and record the current layout in order to gain a clear picture of the current structures. The methodology also included analyzing the processes in logistics and production, including the clean room. Based on this, a potential analysis of the assembly and logistics processes was carried out in order to identify areas for optimization. In conjunction with the material flow analysis, synergy effects were identified in the production areas.
In the next step, the team developed a target image for future processes in production and logistics areas. An analysis of capacity development and inventory led to assembly and warehouse and logistics dimensioning. This was supplemented by the development of a future clean room concept. On this basis, different layout variants were developed, which were compared in a structured evaluation process. A preferred variant was determined in the evaluation. Finally, an implementation roadmap and a cost estimate were drawn up for this variant. The project team worked together intensively and regularly. The target image was developed in three workshops, solutions for the future block layout were discussed and finally the developed variants were optimized and evaluated. The target image workshop was supplemented by a keynote speech on future technologies by ifp consulting.
Solution
In the project, a total of nine variants for a future plant structure concept were developed together with the VBM project team. These concepts combine solutions that ensure an efficient material flow, use synergies between production areas, create optimized warehouse and logistics structures and take into account requirements up to 2035. In the evaluation of the variants, one solution clearly stood out from the other concepts with a degree of fulfillment of 86%.
Result
As part of the project, a clear separation of storage and logistics areas as well as the production areas was implemented. All production and storage areas were arranged to optimize the flow of materials in order to ensure efficient processes.
Despite growth over the next few years, it was possible to reduce the assembly area compared to the current level by adapting the concept. A key component of the concept is the construction of a new logistics hall directly adjacent to the existing building structure. In addition, a central clean room was created to replace the current two clean rooms and create synergies in the immediate vicinity of the packaging area. The central location of the cleanroom and packaging has enabled additional efficiency potential to be realized. In addition, further conversion measures were planned in the building in order to tap into optimization potential in the other production areas.
The result is a concept that takes up the ideas of the VBM project team, uses the experience of ifp consulting and thus creates a solution that is supported by the entire operational project team at VBM.
Cooperation and outlook
Efficient processes and growth opportunities
The new plant structure concept offers VBM the following advantages thanks to the structural change in the existing plant and the addition of a new warehouse and logistics hall:
Enquire now without obligation!
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!
