Site planning and relocation of production

Initiation and project organization

We bring structure to your location planning

A new production site is a complex and time-critical project. Almost all specialist departments and the management of your company are required and must be involved in the project. Only through the interaction of the various factors will you be able to provide and ramp up all company functions, processes and infrastructure at the new location in time for the start of production.

Regardless of whether you have already started the strategic and operational location planning or are still in the discovery phase: With our proven project structure with 13 sub-projects, over 90 work packages and more than 950 individual activities, we create an optimal project organization in the shortest possible time. With active stakeholder management, we align the project with your requirements and ensure that your goals are the focus of the project.

Our service packages:

• Align goals and requirements with stakeholders and management
• Develop a comprehensive project plan
• Determine staffing and project organization

Your benefit:

1. Ensuring success with a tried-and-tested sample project plan for setting up production sites
2. Rapid creation of an optimal project organization
3. Early involvement of all necessary specialist departments

Project management and PMO

We support you with experience, methods and leadership

A large project organization has worked long, hard and successfully when all the gears mesh perfectly at the planned start of production and the first products have been completed. Project management and the PMO have a key role to play here: they control and monitor the many project employees and external partners in terms of content, time and money. They must be aware of the risks, keep an eye on them and mitigate them. And in critical situations, they communicate appropriately and clearly. This is particularly the case in the event of a relocation if the change in the workforce raises social issues and reduces the willingness to cooperate.

Our project managers for your new production site are managers with strong leadership skills and several years of experience in site planning, construction and production relocation. They report directly to the top management of your company. Project management is supported by the PMO, which monitors all project activities on schedule using Microsoft Project and regularly evaluates important milestone dates and the critical project path.

Our service packages:

• Managing and taking responsibility for the overall project
• Leading teams and coordinating external partners
• Monitor results, deadlines and budget
• Active risk and change management
• Communicate regular project reporting

Your benefit:

1. Experienced leaders for your project
2. You benefit from our expertise and best practices in location planning and development
3. Permanent transparency about the progress of the project
4. Structured templates for informed decisions in the project
5. Mistakes and pitfalls are avoided

Technical site planning

Structure and innovation for your new production site

Technical site planning is particularly time-critical at the beginning and ideally begins in the final phase of site selection for companies. The design of the layouts of the production, logistics and functional areas and the definition of the technical building requirements are the prerequisite for signing the lease or work contract for the property. The planning must already take into account the local regulations for construction and operation, as well as the expandability of the new production site. Technical site planning in the early phase of the project therefore has a major influence on compliance with the planned start of production.

As technical consultants, we master factory planning in all phases from conception to ramp-up, as well as change and innovation. This is how we design an efficient and adaptive production system for your new production site. To do this, we focus on innovation and use digital planning tools to avoid information gaps between the many parties involved and to speed up the planning processes. Throughout the entire design and planning process, we continuously evaluate the investments and costs and consolidate the figures with project controlling.

Our service packages:

• Develop production system (machines, automation, processes, material flow)
• Plan the structure of the site with functional and ancillary areas
• Continuously evaluate investments and costs

Your benefit:

1. Strategic location planning based on your objectives
2. Future-proof design of the new production site
3. Optimum factory planning from experts
4. Efficiency and innovation of your new production

Processes and organization

We develop business processes and organizational structure for your new location

The new production site must be integrated into your company’s ERP structure in terms of processes and systems. To do this, new instances and master data must be defined and existing planning and control processes adapted. When designing the business processes in procurement, planning and scheduling at the new production site, you should create advantages by eliminating old process weaknesses and getting closer to the standard of your industry.

Furthermore, the design of an optimal organizational structure and its implementation is crucial for success. Based on the roles and responsibilities, job profiles are developed and suitable candidates are recruited. Key positions are filled first, while the majority of the workforce is recruited in the months before the start of production. Tailor-made training and induction programs are required to train the employees.

With our Business Applications team, we support your specialist departments in the design of future business processes. In doing so, we draw on our expertise in ERP systems, modules and business process design. At the same time, we support your HR department in developing the organizational structure, job profiles and qualification programs.

Our service packages:

• Design adaptation of existing business processes and systems
• Develop business processes for the new location
• Develop organizational structure and prepare onboarding

Your benefit:

1. Seamless integration into your existing systems
2. Efficient processes for the new location
3. Creation of an efficient organization

Finance and budget

We always focus on the profitability of your new location

Like all your investment projects, your new production site also has an amortization target. In order to achieve this, reliable planning and control of investments, expenditure and costs (e.g. wage costs) is required during the course of the project. For most companies, subsidies are also an important financial component that must be applied for and tracked. In addition to these project-related activities, it is also important to define the financial flows of the future location within the group in the context of the respective tax and customs law systems.

We support your finance, controlling and tax experts in the project-related issues of relocation. We contribute our expertise and our local partners. In this way, we create the basis for your management to make the necessary project decisions. Together, we keep the project budget on track and lay the foundations for the economic success of your new production site.

Our service packages:

• Support the financial area of your company
• Planning investments and monitoring costs
• Applying for and tracking subsidies
• Shaping financial flows

Your benefit:

1. Reliable and transparent financial planning
2. Utilization of optimal funding opportunities
3. Expert support in the organization of financial flows
4. Sustainable economic success of your location

Permits and regulation

We work with you to create the legal requirements for the start of production

The same applies in foreign countries: no production without permits. However, the legal requirements often differ from local standards. It is therefore important to consider the country-specific approval processes and operating regulations for industry as early as the project design and site planning stage. Factors relevant to industry include, for example, workplace regulations and environmental impact assessments. Both should be clarified and considered before construction begins. A structured approach is essential in order to maintain an overview.

We identify the necessary building, environmental and operational permits and relevant regulations for your new production site. As part of the application process, we coordinate the specialist departments and act as the interface with the authorities. We support you with our practical experience and our local network. In this way, we create the basis for a smooth start-up and ramp-up of your new site.

Our service packages:

• Identify relevant permits and regulations
• Keeping an eye on required documents and deadlines
• Coordinate specialist departments and communicate with authorities
• Transparently monitor and report on the progress of ongoing procedures

Your benefit:

1. Overview of all required approval processes
2. Seamless integration into the overall project plan
3. Professional support during the procedures

Relocation of production

We ensure a seamless relocation

Relocating production to a new site is far more complex than the move itself, even if the process usually only takes a few weeks. In particular, the dismantling and assembly of large machines and systems is a technical challenge when it comes to starting up sensitive production processes under new environmental conditions (temperature, humidity, adjustment). Nevertheless, deliveries to customers must not be interrupted, even if production is customized. The success of the relocation therefore depends equally on preparation and implementation.

With the knowledge and experience gained from various production relocations, we work with you to draw up a clear relocation plan including advance production and buffer stocks. In this way, we ensure a fast relocation without any delivery failures. During the ongoing relocation, we roll up our sleeves and support your team. We coordinate the various activities and make the best decisions in the event of unforeseen deviations.

Our service packages:

• Develop a staged relocation plan
• Create a detailed relocation plan for all machines, appliances and equipment
• Coordinate employees and partners involved
• Operational control of the move

Your benefit:

1. Minimal risk for relocation
2. Uninterrupted supply to your customers
3. Professional and reliable control

Commissioning and start-up

Your new production site goes online

The start of production and the subsequent increase in output during the ramp-up always pose major challenges for the industry. Employees take many machines, systems and production processes online in a short space of time and run initial pilot series. In some cases, certification procedures are required. Subsequently, process and product quality are constantly improved to increase efficiency and reduce waste. Production output increases continuously until the assembly line is reached.

We support you in achieving the planned performance level step by step. By continuously monitoring the machine and system coordination, we ensure that the commissioning of your production runs smoothly. At the same time, we help you to ramp up and stabilize the material supply. With our trained eye, we support you in further increasing efficiency through improvements and minimizing rejects and rework. This allows you to remain adaptable to short-term changes throughout the entire ramp-up.

Our service packages:

• Plan quantity structure, safety stocks and ramp-up curve
• Set up workstations, train employees and coordinate material supply
• Solve problems as quickly as possible
• Identify possible improvements, implement measures immediately

Your benefit:

1. Involvement of all parties
2. Effective problem solving directly on site
3. Quick, coordinated reaching of the ridge line

What are the advantages and disadvantages of relocating?

Relocation can reduce costs, improve market access and integrate modern technologies. Disadvantages may include high investments, production interruptions and possible resistance from the workforce.

How can risks be minimized when relocating? 

A detailed relocation plan with advance production and safety stocks ensures uninterrupted market supply. Close coordination of all parties involved enables a rapid response to unforeseen problems. In addition, experienced project managers and structured risk management help to identify and resolve potential challenges at an early stage.