Factory and layout planning: consulting, simulation, implementation
Achieve better results in factory and logistics planning with EFESO
Greenfield and brownfield factory planning: from the idea to a resilient concept
A look at many locations shows that plant structures survive for a long time. It is therefore particularly important to proceed with prudence and professionalism and to involve the right partners when planning a factory - be it a new building or a conversion.
In the beginning is the idea. We are happy to share with you our ideas of a factory of the future. From our point of view, layout and infrastructure must enable efficient flows, promote cooperation between employees and support the joy of creating value. To ensure that a factory is still one of the best in 50 years, we rely on the following key elements:
- Modular, so that you can grow and properly integrate value creation partners
- Flexible, because products and technology change
- Optimal in terms of material and information flow
- Smart and digital
- Energy Efficiency, CO2-neutral and resource-saving
Agile approach to planning the zero-impact factory
Before the excavators roll, the ideas must be developed into robust concepts and concrete layouts. This is not possible without the involvement of stakeholders, who demand coherent concepts and a convincing business case based on several comparative scenarios. Here it is important to work out the potentials on all levels in concrete terms and to evaluate them in a comprehensible way.
Sustainability aspects play a major role in modern factory and logistics planning. Under the generic terms “zero-emission factory” and “zero-impact factory”, various environmentally friendly measures are implemented, ranging from the reduction of energy and water consumption, CO2 and VOC emissions to waste management and soil protection.
In order to achieve a high level of planning efficiency and to manage risks in the course of the project with foresight, an iterative and agile approach is recommended. It is carried out according to the following guidelines:
- from the central (value-added process) to the periphery (outdoor facility)
- from the rough (general planning/plant structure planning) to the fine (workplace design)
- from the ideal (Greenfield) to the real (Brownfield)
This ensures that unnecessary discussions at the beginning (e.g. about the colour scheme of the offices) do not slow down the overall process significantly. Experience has shown that the desires of all those involved are great when it comes to new planning and replanning. We take great care to ensure that the planning focuses on the key issues and take particular account of the impact on the building structure, the level of investment and the potential for improvement.
EFESO used a virtual factory to demonstrate new scope for revising a concept for a multi-storey greenfield factory.
A “one-stop-shop” solution covers all planning strands - the video shows main room formats and examples from process simulations for production and logistics.
Efficient factory and layout planning
Benefit from the expertise of the EFESO team in factory planning, layout planning and plant structure planning. Whether greenfield or brownfield: together we create a future oriented site planning.
START PLANNING CHECK Realizing best-in-class factories with EFESO: six fields of action for factory planning and layout planning
EFESO supports you from the first planning idea to the start-up of the factory or logistics centre. This ranges from strategy development and site selection in the run-up to the entire project implementation to the onboarding of local suppliers in the ramp-up phase. Our range of services includes:
1. Location search and selection
- Selection of suitable regions (factor costs, labor market and supplier structures, infrastructure, regulatory framework, economic development).
- Search for suitable properties (land, building developers, existing properties).
- Recruitment of personnel for the planning and construction phase.
- Technical due diligence of properties and locations for technical feasibility and risks.
- Brownfield / greenfield projects: Differentiation and specialized approaches for existing sites versus new builds.
2. Production and logistics concepts:
- Future-oriented value streams in manufacturing and assembly.
- Line and plant planning.
- Material supply and disposal systems.
- Storage and transportation systems.
- Preparation of tenders.
- Supplier selection and integration.
- Planning of inventory management concepts.
- CapEx planning: consider capital expenditures (CapEx) in production in the planning phase, for example with regard to capacities and space productivity.
- Dimensioning and technology integration: detailed dimensioning of production facilities and integration of specific technologies.
- Infrastructure and supply planning: planning and integration of energy, water and supply systems in production.
- Material flow and logistics simulation.
Project example greenfield factory I:
Planning of a new factory under sustainability criteria
Manufacturer of electronic components / employees: approx. 1,000 / turnover: approx. 180 million EUR
Project tasks / focus:
- Planning and construction of a factory that combines production, logistics and administration under one roof.
- Optimization of the production flow over five stages on an area of 10,000 m² to minimize distances and improve efficiency.
- Integration of e-mobility, renewable energies and CO₂ reduction strategies into the factory's design and operating concept.
Results:
- Sustainable factory design with photovoltaic systems, e-mobility infrastructure and measures to improve CO₂ consumption.
- Optimized production flow: short distances, efficient logistics and scalability with ~3,000 m² expansion potential.
- Holistic project implementation: consideration of a wide range of aspects from building planning and production layout to future space utilization.
Project example greenfield factory II:
End-to-end factory and intralogistics concept
Tobacco products manufacturer / employees: approx. 80,000 / turnover: approx. EUR 35 bn.
Project tasks / focus:
- Planning of a new factory site, including definition of intralogistics and automation concepts for the factory.
- Evaluation of logistics scenarios, definition of layout definition and estimation of investment costs for key systems.
- Focus on highly efficient logistics to support growth targets and ensure scalability for future expansion.
Results:
- Data review and requirements clarification through workshops as a basis for concept development.
- Development and evaluation of logistics and warehouse alternatives; definition of the ideal solution.
- Finalization of the material flow and factory layout, including automation potential, warehouse dimensioning, risk and personnel requirement analysis and CapEx assessment for core logistics systems.
3. Scenario and layout planning:
- Master planning scenarios and expansion options for locations.
- Design and detailing of the overall layout: greenfield and brownfield, rough and detailed concept.
- Area and spatial planning for value and support areas, infrastructure, office spaces, social areas and outdoor areas.
- Determination of the building structure.
- Digital planning in 2D and 3D.
- Scenario evaluation: economic efficiency calculations and concept simulations.
4. Smart Factory:
- Horizontal integration from product design to delivery / paperless factory.
- Advanced operator support, cobots and exoskeletons.
- Digital visualization in the factory.
- Automated storage and retrieval systems / Smart Automation.
- (Partially) autonomous transport of materials and assemblies.
- Open / flexible office concepts.
- Requirements on the IT infrastructure.
Project example brownfield factory:
intralogistics optimization & layout design
Tobacco products manufacturer / employees: approx. 80,000 / turnover: approx. EUR 35 bn.
Project tasks / focus:
- The company is significantly expanding its Reduced-Risk Products (RRPs) business.
- As part of a brownfield expansion, intralogistics and automation in the factory and warehouse areas will be reviewed.
- Evaluation and validation of the existing logistics and automation concept.
- Focus on high-efficiency logistics.
Results:
- Proven methods enable fast implementation and early value creation.
- Direct transfer from planning to execution based on validated best practices.
- Experience-based planning minimizes ramp-up challenges and ensures smooth go-live.
- Integration of automation and Industry 4.0.
Brownfield planning
Benefit from the expertise of the EFESO team in factory planning, layout planning and plant structure planning. Let's create a future oriented site planning together.
START PLANNING CHECK 
5. Zero Emission Factory / Industrial Sustainability:
- Energy-efficient technologies and production facilities.
- Sustainable supply concepts.
- Planning of low-emission buildings and infrastructure (CO2-neutral).
- Energy recovery concepts.
- Circular economy.
- Building certifications according to international standards (DGNB, BREEAM, LEED).
6. Implementation support:
- Tendering, supplier selection and awarding.
- Coordination and support during production ramp-up.
- Qualification concepts and training for employees and suppliers.
- Project management and project controlling.
- Claim and risk management: processes for actively handling project risks and claims during the construction phase.
- Handover management: clear processes for handover and ensuring operational readiness after completion of the construction and realization phase.
Digital twins and simulations of the architecture and processes support optimal factory planning.
Our video of a digitally designed factory for the production of eV battery cells shows which elements such a simulation can contain, for example.
CUSTOMER QUOTES - PROJECTS FACTORY PLANNING & LAYOUT PLANNING
»We have worked together with EFESO in a relationship built on trust for decades – including in 2024 as part of our plant structure planning. The plant structure is a key element in supporting our future growth. The EFESO team contributed its expertise in a highly results-oriented way, particularly through its deep know-how in factory planning and its understanding of how a plant operates in our industry. Our expectations were fully met. In particular, the 3D visualization of the plant structure significantly enhanced internal understanding of the proposed solution. «
»It has been a genuine pleasure collaborating with the EFESO team during the initial phase of our factory expansion project. From the start, we’ve appreciated the clear communication, collaborative spirit, and strong commitment to delivering results. The progress made during the initial phase has given us a solid base to build on, and that’s one of the main reasons of the success of this project. I’m happy to share this feedback… it’s been a great partnership so far.«
»EFESO provided valuable support through a comprehensive concept and design review for our future manufacturing site, encompassing the building layout, production setup, and logistics. Their structured methodology and strong operational expertise helped us validate and optimize the production layout while accurately defining the logistics requirements. The results formed a solid foundation for our investment decision.«
»EFESO was the ideal partner for our factory project in Hungary. Their expertise in site identification, production planning, and managing all aspects of the project master plan, from permits to factory ramp-up, ensured everything ran smoothly. EFESO’s ability to handle complex requirements made them the perfect partner for our expansion.«
A manufacturer of turbine components creates with EFESO the complete factory planning for a new site in Eastern Europe.
The video shows the specific project requirements and the digital simulation of the factory.
CASE STUDIES & INSIGHTS - PRACTICAL EXAMPLES
Smart Factory Planning: Smart Planning for smart Factories
CASE STUDY:
What does the ideal factory of the future look like? Do products there control their production completely independently? A pharmaceuticals and life sciences company plans the main directions for the smart factory transformation of four plants in just one month. Together with EFESO, the project team creates a "big picture" as a basis for planning and tests three prioritized technologies in pilot projects.
Factory and logistics planning
CASE STUDY:
An automotive supplier consolidates four parts warehouses into one warehouse. Three distribution centers of a company from the automotive industry should be integrated into an existing fourth. With the support of EFESO, the company mastered this task in eight weeks. To do this, it developed five solution scenarios with different degrees of automation (“minimal invest” to “fully automated”) including layouts and monetary evaluation.
Sales and Operations Planning
CASE STUDY:
A wood processing company wanted to improve its planning quality while reducing planning efforts. EFESO developed a suitable solution concept for an S&OP process based on SAP IBP (Integrated Business Planning), allowing the planning process to be standardized and automated, as well as bring about more flexibility and increasing efficiency. An intensive dry run was carried out in the first stage of the project.
Blueprint for the Sustainable Factory
CASE STUDY:
A global supplier for the textile industry sets new standards in the sustainable design of its production facilities. EFESO accompanies the construction of a new factory in Bangladesh as a sparring partner and identifies together with the client potentials to reduce the use of resources and CO2 emissions as well as to increase workplace attractiveness. The result is a lighthouse factory that serves as a model for other factories of the company in terms of social and ecological sustainability.
Sustainability update for the global production network
CASE STUDY:
In order to achieve the sustainability targets it has set itself, an automotive supplier must optimize its more than 70 existing plants worldwide in terms of emissions and resource consumption. Together with the customer, EESO develops an overarching target picture to evaluate the maturity level and derive a sustainability roadmap for all sites.
Restart for Greenfield Planning
CASE STUDY:
An electronics manufacturer aims to secure a leading position in a future market in the Middle East with a new greenfield plant.
Together with EFESO, the company challenges the existing layout and concept – even though construction has already begun. With a digital building and process twin, the planning process is successfully restarted – despite the extremely tight timeline.
Factory Planning – Time for Performance Programs
INSIGHT:
EFESO supports companies in the end-to-end realignment of their production network – from ideation to ramp-up. As a one-stop shop, we offer strategic, efficient, and hands-on support for every stage of your factory planning.
Design and Realization of Distribution Centers (DCs)
INSIGHT:
Learn about the key success factors for integrated distribution centers and agile, resilient supply chains.
eV Battery Cell Factory
INSIGHT:
Discover how we successfully plan and execute factory projects using a ‘one-stop-shop’ approach, as demonstrated in an EFESO project for a 5 GWh battery cell factory.
Factory Layout Optimization
INSIGHT:
Leverage our expertise in factory layout redesign. This insight summarizes real-world project examples and tangible outcomes from the automotive, mechanical engineering, and other industrial sectors.
Construction Material Industry in Central Eastern Europe
INSIGHT:
Leverage EFESO’s deep expertise in the Central and Eastern European market to future-proof your factories and value creation networks in the construction materials industry. This insight summarizes key findings from current market analyses and uses specific KPIs to demonstrate the tangible results that can be achieved with EFESO’s approach in each of the five phases.