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.
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.
This EFESO factory planning project focused on fully integrating the manufacturing operation with internal logistics and building features.
The company benefited from improvements in space planning, production processes and a modular layout design with potential for future flexible expansion.
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
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.
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
»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.«
»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. «
»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.«
»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. «
»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.«
