Layout planning
Sustainably increase productivity and efficiency with targeted layout planning
Well thought-out layout planning is more than just arranging machines or warehouses – it is the key to sustainably increasing the productivity, efficiency and competitiveness of your factory. After all, how material flows are routed, which areas are used and how processes are coordinated with each other is crucial to costs, throughput times and flexibility.
Modern layout planning therefore combines technical expertise, digital tools and strategic thinking: from the rough layout to the detailed fine layout to the simulation of the entire production and logistics processes. The result is a future-proof factory layout that not only meets current requirements, but is also prepared for an increasing number of variants, new technologies and growing production volumes.
Layout planning in volatile and complex conditions
Companies today face enormous challenges when designing their factory layouts. Increasing product individualization, volatile sales volumes and a high number of variants require flexible layouts that can be quickly adapted to changing conditions. Static planning is reaching its limits here: production and logistics areas must be modular, conversions must be possible during ongoing operations and new technologies such as robotics and driverless transport systems must be integrated from the outset.
At the same time, space requirements are becoming increasingly critical. Especially in existing production facilities (brownfield projects), only limited space is available and rising construction and energy costs are increasing the pressure for compact, efficient layout solutions. Multi-storey concepts, optimized block layouts and material flow analyses are therefore essential in order to make optimum use of the available resources.
Modern layout planning also takes into account the requirements for sustainability and energy efficiency: efficient material flows, CO₂-reduced processes and resource-saving arrangements help to reduce overall operating costs and meet environmental targets at the same time. A high-quality database is crucial for precise planning: only with complete information about machines, production areas and logistics processes can simulations, visualizations and planning decisions be carried out reliably.
Philipp Carl
Senior Manager Logistics
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What is layout planning and how does it work?
Layout planning is the systematic design and spatial arrangement of production, logistics and ancillary areas of a factory in order to optimally coordinate material flow, space requirements and processes. Successful layout planning combines technical, organizational and economic requirements and creates flexible, scalable structures that also take future developments into account.
The creation of a rough layout forms the basis on which the arrangement of machines, workstations and material flows is optimized in the detailed layout. Visualization methods and digital factory models make it possible to check different scenarios, identify bottlenecks and increase efficiency throughout the entire production process. In this way, layout planning becomes a strategic tool that cuts costs, reduces throughput times and supports growth.
Factory planning: The structural framework of layout planning
Factory planning forms the structural framework for the entire layout planning. It includes the factory structure, the arrangement of production areas, machines and equipment as well as the design of efficient material flows within the factory. The aim is to make production efficient, flexible and economical – both for existing sites and for new buildings.
Factory planning initially focuses on the rough layout and zoning of the production areas. This defines which areas are intended for production, assembly, logistics and warehousing and how these are spatially coordinated in order to minimize transport routes and optimize material flows. This is followed by detailed layout planning, in which the exact position of machines, workstations, storage areas and conveyor technology is determined. Block layouts are used to efficiently structure connected production and logistics areas.
A central element of factory planning is the consideration of future requirements: Layouts are designed in such a way that extensions, conversions and adaptations to new products or technologies are easily possible. At the same time, aspects such as space requirements, energy efficiency and the integration of logistics processes are incorporated into the planning. This holistic approach is the only way to create an efficient, flexible and future-proof factory layout that increases productivity and reduces costs for material movements, transportation and operating resources.
Logistics planning as a central component of layout planning
Logistics planning is a central component of layout planning, as it ensures that material flows, storage areas and transportation processes are optimally coordinated with production. An efficient arrangement of warehouses, conveyor technology and material routes minimizes throughput times, reduces inventories and enables flexible reactions to fluctuations in demand.
Digital tools support the simulation of material flows and the creation of visualizations that identify bottlenecks at an early stage. The integration of automation technologies such as driverless transport systems or conveyor technology is also taken into account as early as the planning phase in order to minimize downtimes and ensure production output.
Central aspects of logistics planning are the optimization of block layouts, the use of storage areas with minimal space requirements and the coordination of transport and conveying processes. Networking with digital control and management systems creates a holistic, flexible layout that increases efficiency, reduces energy consumption and supports sustainable production.
What is layout planning in the factory?
Layout planning is the systematic arrangement of machines, workstations, storage and logistics areas in order to efficiently design material flows, transport routes and processes. Modern layout planning uses digital tools such as 3D factory models, material flow simulations and visualization tools to optimize rough and fine layouts, identify bottlenecks and create flexible, scalable layouts. The result is a future-proof factory layout that meets current requirements and enables adaptations to new products, technologies or an increasing number of variants.
What phases are there in factory and layout planning?
Layout planning is divided into several phases:
Simulation and visualization: checking material flows, identifying bottlenecks and evaluating different scenarios.
This structured approach ensures that the factory layout is efficient, flexible and future-proof – both for new buildings and existing sites (brownfield).
Rough layout: Initial structuring of the production areas, logistics zones and storage areas.
Detailed layout: Detailed positioning of machines, workstations and conveyor technology.
What is the difference in the production layout between workshop production and flow production?
The choice of production layout depends heavily on the type of production. In workshop production, machines are grouped according to function, which enables a high degree of flexibility with a wide range of variants, but entails longer transport routes and throughput times. Flow production, on the other hand, arranges machines and workstations along the production flow, which shortens material flows and reduces throughput times. A targeted production layout takes these differences into account, optimizes storage and transport areas and ensures efficient production processes.
