Factory and Logistics Planning

The planning of new factories, or the restructuring of existing sites, is a mammoth task for any manufacturing company.  The decisions that are made during this planning have long-term consequences and later changes are only possible with enormous time and resources. And sometimes they are not reversible at all. Therefore, factory planning should be done with the maximum possible care and professionalism. Multiple factors need to be considered.

For example, the involvement of all relevant stakeholders is necessary in the planning of infrastructure, logistics and manufacturing concepts, all the way up to the relevant products. Both within the company and beyond. Upstream and downstream partners in the value chain are particularly important, as are the competent authorities and institutions that set the conditions and restrictions for the construction or the refurbishment of a factory.

An iterative and multi-dimensional approach is therefore advisable in order to do justice to this complexity, to proactively manage risks over the course of the project and achieve high planning efficiency. The product and its variance define the optimal core process from which all logistical and infrastructural processes and structures are derived. Optimal planning takes place along the following dimensions:

  • Central/peripheral: From the manufacturing process to disposal, from main process to secondary process
  • Coarse/fine: From general structure to building, area, resource structure
  • Ideal/realistic: From greenfield scenario to brownfield planning with constraints

ROI helps companies in the manufacturing industry in the process of planning of factories and logistics networks. From strategy development and site selection, the design of manufacturing and logistics concepts and Industry 4.0 road maps, to the derivation of infrastructure requirements as well as personnel planning and organisation. We actively support the entire project implementation as far as the manufacturing ramp-up and onboarding of local suppliers. Our services in detail:

Location search and selection

  • Infrastructure, regulatory environment, economic development
  • Local labour market and supplier structures

Manufacturing and logistics concepts

  • Optimisation of process chains and value streams in production and assembly
  • Plant, factory and logistics planning
  • Planning and implementation of Industry 4.0, smart factory and IoT concepts
  • Supplier selection and integration, planning of inventory management concepts

Layout planning

  • Development and successive detailing of the overall layout: Rough and detailed concept
  • Area and spatial planning
  • Determination of building structure
  • Scenario evaluation: Economic viability calculation and concept simulations

Implementation support and HR development

  • Supplier selection and coordination
  • Regulatory approval management
  • Support during manufacturing ramp-up
  • Qualification concepts and training sessions for staff and suppliers
  • Project controlling, project management and project office