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Implementation planning & realization of plant layout optimization

Constantly increasing flexibility and productivity requirements forced our customer to re-align and better integrate processes in manufacturing and logistics. Besides a historically grown plant structure, the increasing demand on a core product segment was to be considered. Through a project to optimize the plant layout, CBC supported the customer in identifying potentials, connecting those with long-term goals in relation to Industry 4.0, and achieving tangible results.

During the analysis phase, requirements for future cycle times within individual manufacturing clusters were analyzed and potential layout options elaborated. For the selection of the desired layout and the identification of further optimization, material flows based on the planned volumes were analyzed and optimization potentials examined. Through its profound knowledge about manufacturing processes and experience in layout design, CBC was capable of preparing an in-depth analysis and detailed recommendations for action for the customer. Key factors considered included future ability through autonomous means of transportation, product flexibility, use of space, and productivity.

After the planning of the new production lines, the reconstruction of the individual line sections was defined together with the customer and structured through work packages and mile stones. Subsequently, the conversion of the line sections were conducted within a time period of six months. The result was, besides an optimized plant layout and sustainable transport concepts, efficiency increase through personnel reduction in the logistics sector by about 30 percent. CBC support also enabled the creation of continuous transparency on the status, possible deviations, and cost effectiveness and on-time project realization.

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