A manufacturer in the special machinery and plant engineering sector was faced with the challenge of integrating a new major order into ongoing production - without additional investment in buildings or infrastructure. The existing production area was already working to capacity, so conventional solutions such as hall extensions or temporary alternative areas were not an option.
New production layout instead of new building
In collaboration with the production team and all relevant stakeholders, we developed a new logistics and space concept. The core of this approach was the complete reorganising of the existing production layout - without affecting ongoing operations.
Requirements, bottlenecks and potential solutions were systematically recorded and integrated during intensive consultations with everyone involved. This not only increased acceptance of the changes, but also enabled the employees' know-how to be used in a targeted manner.
Flexible space utilization
Clearly defined material flows, a modified arrangement of the systems and the targeted use of logistical buffer areas resulted in a significantly more efficient use of the existing production area.
Thanks to the new layout, the additional order could be fully integrated - without any structural investment. At the same time, space efficiency was significantly increased: turnover per square meter of production space rose by 35%. In addition, investments totalling EUR 1.9 million were saved.
The clean room production for plastic components was relocated from Germany to Slovakia within three months.This includes ramping up wafer equipment, digitalising process data, making ERP adjustments and training the team.
An automotive supplier was sued in the USA. The supplier had been missing important documents. The lawsuit resulted in high costs. A structured analysis and and clear processes can create legal certainty and optimise inefficient workflows.
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