Practical factory planning – systematically achieving the optimal production layout
Seize opportunities – even on brownfield sites
Designing an efficient, sustainable production layout is a key challenge in the course of industrial transformation. The increasing complexity of products, variety of variants, and the need for flexible manufacturing concepts require systematic approaches to factory planning and automation.
The opportunity presented by brownfield sites, and thus also in the area of production conversion, should not be overlooked. Here, too, potential can be leveraged at various levels. On the one hand, these are classic issues such as reducing throughput times, optimizing inventory, and increasing productivity. On the other hand, more ergonomic workplaces, a higher degree of automation, or support from assistance systems can be the answer to the shortage of skilled workers.
Based on CIM Aachen’s project experience, a four-phase process model has emerged as a structured methodology for gradually progressing from the analysis of the product portfolio and the assessment of the current situation to the design and economic evaluation of an optimized layout.
Product analysis for production segmentation
The first phase is dedicated to product analysis. The aim is to segment the existing product range into homogeneous product families that are similar in terms of process sequence, resource requirements, and cycle times. This homogeneity forms the basis for standardization and thus for economically viable automation. Using proven methods such as ABC analysis and the product family matrix, the segments with the highest volume and turnover and the greatest potential for automation are identified. Products whose production processes differ greatly from one another, on the other hand, are difficult to convert into standardized processes. Here, it is necessary to weigh up the extent to which technical possibilities can be reconciled with economic conditions.
Process and key figure analysis as a starting point
This is followed by the second phase, the foundation. In this step, the current state of production is systematically recorded using value stream analysis. The subsequent analysis of process indicators in combination with the recorded material and information flows enables a differentiated assessment of the efficiency of existing processes. Creating transparency with regard to time and cost structures makes a decisive contribution to developing realistic and economically viable improvement measures.
Production layout and technological leap
In the conceptualization phase, the third stage of the model, an ideal target value stream is developed. Based on this, a technological concept is developed that encompasses the use of modern automation technologies, digital tools, and efficient manufacturing strategies. In addition, a material flow and logistics concept is developed that takes into account, among other things, supply strategies (e.g., just-in-time, Kanban), the connection of warehousing and shipping, and digital control systems. The aim is to ensure smooth production processes through short distances, intelligent automation, and future-oriented infrastructure, such as 5G. A combination of creative tabletop workshops and professional planning tools such as visTABLE® is ideal for participatory layout planning. This allows simulations to be carried out, variants to be compared, and the effects of planned changes to be evaluated at an early stage.
Focused on the goal
The fourth phase concludes the process: the implementation roadmap. The focus here is on economic evaluation. This ensures that technical measures are not only feasible, but also economically viable. Investment calculations, scenario comparisons, and risk analyses are used to verify whether the developed layout will achieve the desired return on investment. The implementation plan takes into account both technical and organizational aspects—from procurement and conversion to commissioning. The result is a well-thought-out roadmap that not only supports companies in redesigning their production structure, but also ensures their long-term competitiveness.
Conclusion
In summary, the four-phase model shows that methodically sound factory planning goes far beyond the mere allocation of space. It combines analysis, strategy, technology, and economic efficiency into a holistic approach. Companies that consistently follow this path not only benefit from more efficient processes, but also lay the foundation for flexible, automated, and digitally networked production in the future.