Production
Factory planning and plant structure planning
Factory planning from conception to realization
Production is the heart of your business. To ensure it remains efficient, flexible, and competitive tomorrow, you need well-thought-out factory, plant structure, and production planning. Increasing product variety, smaller batch sizes, and shorter product life cycles make it necessary to regularly reevaluate and refine existing structures. Whether you’re reorganizing an existing production facility or planning a new factory, we’ll support you from the initial idea through to successful implementation. Drawing on our experience from numerous projects, we lay the foundation for higher productivity, lean processes, and sustainable growth.
Project management
We hold all the strings in our hands
The planning and realization of a factory is a complex project in which many people and companies are involved. Professional factory planning therefore requires the work of all disciplines – from the production specialist to the architect – to be continuously and systematically coordinated so that the numerous tasks are completed in a structured and timely manner.
Our experienced project management colleagues provide technical and methodological expertise from the work planning to the implementation phase. Regardless of whether you only need help coordinating individual tasks or are looking for someone to take on overall project management: Our IPMA-certified project managers will provide you with the support you need.
Service packages
- Develop and control project schedule
- Coordinate project activities
- Ensure communication
- Continuously monitor trades
Your benefit:
- Technical and temporal conformity of the results
- One contact person for all project matters
- Frees you up for your day-to-day business
- Reliable and needs-based information
Philipp Kappus
Production Manager
Talk to me!
Are you looking for an experienced partner with cross-industry expertise and innovative tools for your factory or plant structure planning? Then please send me your message. I will get back to you as soon as possible.
Site selection
The best possible location for your factory
Numerous factors play a role in deciding where to locate your new factory: is there a sufficiently qualified workforce in the region (or is it attractive enough to attract workers?), what about the level and development of labor costs, are there customers or suppliers nearby, are there any government subsidies?
This multitude of relevant aspects often makes an optimal decision even more difficult. With our experience and our tried-and-tested, systematic approach to factory planning, we will be happy to cut a path through the numerous data and information for you.
With our in-house regional database, we can quickly identify relevant location options and evaluate them reliably. Our local partners also contribute their local expertise; with our extensive network, we further support your search for a location.
Together with you, we continuously narrow down the selection in a transparent process so that you can make a comprehensible, well-founded and best possible decision for a particular location.
Service packages
- Identify relevant location factors
- Create a longlist of possible locations
- Narrow down the shortlist with the Rothbaum regional database
- Visit possible locations on site
- Supplement background information via large network of local partners
- Create a comparative economic calculation
Your benefit:
- Comprehensive search process
- Fast, precise and independent location assessment
- Securing the location decision through local expertise
- Comprehensible basis for decision-making
- Networking with implementation partners
Plant structure planning
The right layout planning for a technical and economic optimum
The layout of your factory has an enormous long-term impact on the profitability and efficiency of the production site. Only with optimal layout planning for production and logistics can processes be streamlined and waste minimized.
We analyse your specific technical, organizational and economic requirements and develop a comprehensive planning basis on this basis, from which we then derive possible structural layouts for the production facility. At the same time, we attach great importance to future-proof dimensioning: What could a phased development plan for the entire site look like?
Together with you, we select the best concept for the factory structure to meet your requirements and then plan this in detail. We use the latest planning software to optimize material flows and space requirements. We design the ideal processes and develop the necessary infrastructure for transportation, storage and provision, integrating innovative automation and logistics solutions into your factory planning.
Service packages
- Create a planning basis
- Developing the ideal structure for the work
- Develop detailed layout planning
- Select production and automation technologies
- Create implementation plan
Your benefit:
- Alignment of factory planning with the company’s objectives
- Comprehensive analysis of current vulnerabilities
- Future-proof design of your production facility
- Planning the optimum building structure based on your individual objectives (3D or 2D models)
- Close cooperation with your production and logistics experts
- Well-founded business case as a basis for decision-making
Plant planning & production technology
Production technology economically designed
The production systems you want to use in your factory must fit in harmoniously with the overall concept of the site. As part of well thought-out factory planning, we ensure that all technologies are coordinated in such a way that process steps are efficiently synchronized. This is the only way to create a consistent and efficient value stream.
We are happy to assist you with plant design, technology selection, and determining the level of automation that is most economically optimal for you. Our focus: flexible solutions that allow you to concentrate on your growth goals. We want to ensure that your production technology remains a competitive advantage even as raw material and energy costs continue to rise.
Service packages
- Analyze product structure and quality requirements
- Select optimal production technologies
- Coordinating production processes
- Simulate complex process sequences
Your benefit:
- Increase the efficiency of your production
- Coordinated production processes with sensible buffers and short throughput times
- Support from requirements management to implementation
- Holistic solution strategy and avoidance of isolated solutions
- Production flexibility tailored to your requirements
Invitation to tender
Wanted: efficient technologies and reliable partners
Whether your new factory planning will be a success depends largely on how you put the necessary tasks out to tender and award them. For complex procurement projects in particular, it is therefore important to keep the tenders precise, but at the same time open to solutions, and then carefully check who and what you select.
The tenders must also be appropriate to the projects: The construction of plants, the acquisition of machines for production – these tasks require a different approach than, for example, the search for a suitable logistics system. We adapt the scope and focus of each tender precisely to the area and your needs.
We are happy to guide you through all of these processes and ensure that the award packages are technically and organizationally coordinated. We work with you to check whether it makes sense to award the contract to a general contractor or a combination of one or more general contractors and planners. We define the technical specifications and functionalities in functional specifications. If you wish, we can coordinate the entire tendering and awarding process for you and take over the communication between your experts and the potential suppliers.
Service packages
- Create specifications
- Identify new technologies and their suppliers
- Check and evaluate incoming offers
- Managing the award process
Your benefit:
- Manufacturer-neutral and objective advice
- Comprehensive market overview of innovative companies and solutions
- Objective evaluation of the solutions offered
- Selection of the most suitable and technically and economically best concept and offer
Realization and training
Factory planning that works – reliable from concept to realization
From the groundbreaking ceremony to the start of production, it’s essential to coordinate numerous companies and individuals to meet deadlines. All construction, assembly, and installation work must be carried out correctly down to the last detail—and you need to keep track of everything.
Our experienced consultants will gladly and professionally guide you through all phases of implementation. We manage the infrastructure work, but also keep an eye on the new demands placed on your employees, for example in production and logistics. We introduce them to working in the new factory with suitable change processes.
Service packages
- Coordinate and monitor procurement and infrastructure work
- Monitor and maintain project schedule
- Planning and implementing change projects
- Ensuring internal and external communication
Your benefit:
- One contact person for all project matters
- Full transparency on the current status of work
- Optimum preparation of your employees included in the project schedule
FAQ
What should companies take into account when undertaking integrated factory planning?
Integrated factory planning considers not only buildings and production areas, but the entire interplay between production, logistics, plant, material flows, infrastructure and organisation. We support you in developing a holistic factory concept based on your business objectives, product structures, volumes and processes, and guide companies from the design stage right through to implementation.
When is a brownfield transformation of existing factories worthwhile?
A brownfield transformation is particularly beneficial when existing buildings, plant or infrastructure are to be reused, whilst at the same time production processes need to be modernised and capacities expanded. Integrated plant structure planning provides the basis for aligning production, logistics and IT with future requirements. Rothbaum Consulting supports companies in analysing existing structures and developing a future-proof factory concept.
Weitere Informationen
Grundlagen einer zukunftssicheren Fabrikplanung
Eine durchdachte Fabrikplanung ist das Fundament für hochproduktive, flexible und kosteneffiziente Fertigungsstätten. Ganz gleich, ob es sich um einen kompletten Neubau, die Erweiterung eines bestehenden Standorts oder die Reorganisation einer vorhandenen Produktion handelt – die Anordnung von Fertigungsbereichen, Lagern und Sozialräumen bestimmt maßgeblich die Logistikkosten und Durchlaufzeiten.
Im Zentrum der Planung steht die Gestaltung optimaler Material- und Informationsflüsse nach Lean-Principles. Eine detaillierte Erfassung von Produktionsvolumina, Produktvarianten und Maschinenbelegungen stellt sicher, dass die räumlichen Kapazitäten ideal genutzt werden und eine hohe Anpassungsfähigkeit an künftige Marktveränderungen gewährleistet bleibt.
Vorteile einer neutralen Fabrikplanung Beratung
Die Komplexität von Fabrikbauprojekten erfordert tiefgehendes Fachwissen aus verschiedenen Disziplinen wie Maschinenbau, Architektur und Logistik. Eine spezialisierte Fabrikplanung Beratung bringt wertvolles externes Know-how ein und unterstützt Ihr Unternehmen unvoreingenommen von der ersten Idee bis zur Realisierung.
Die Berater erarbeiten unterschiedliche Layout-Varianten, bewerten diese anhand klarer wirtschaftlicher und funktionaler Kriterien und simulieren Materialflüsse. Dadurch werden Fehlinvestitionen vermieden und ein optimaler Flächennutzungsgrad erzielt. Zudem sorgt die neutrale Begleitung für eine reibungslose Abstimmung zwischen den internen Fachabteilungen und externen Fachplanern oder Bauunternehmen.
Realisierung und nachhaltige Prozessintegration
Nach dem Feinkonzept folgt die strukturierte Umsetzung des Fabrikprojekts. Eine erfahrene Fabrikplanung Beratung übernimmt das Projektmanagement, überwacht Kosten sowie Termine und koordiniert die Installation von Produktionsanlagen und Infrastruktur. Besonderes Augenmerk liegt dabei auf der Minimierung von Produktionsunterbrechungen während Umbaumaßnahmen im laufenden Betrieb.
Nach der physischen Fertigstellung begleiten die Experten den Hochlauf der Produktion und die Feinabstimmung aller Arbeitsabläufe. So entsteht eine moderne Fertigungsumgebung, die ergonomische Standards erfüllt, Ausfallzeiten minimiert und die Produktivität Ihres Standorts nachhaltig steigert.
