The ebp-consulting approach to factory structure planning
A future-proof factory structure forms the functional backbone of any high-performance and scalable industrial production. To ensure your long-term competitiveness, we systematically analyse and optimise all internal processes, from the strategic network level right down to the individual workstation. Drawing on our in-depth engineering expertise, we act as a holistic partner covering the entire methodological spectrum of plant layout planning:
- Strategic plant development: Long-term site security and capacity planning.
- Plant layout planning & definition of building structures: Centimetre-precise layout for efficient use of space.
- Value stream analysis & value stream design: Elimination of waste and reduction of lead times.
- Comprehensive material flow concept & production logistics planning: Alignment of production and logistics for transparent and stable processes.
- Traffic route planning: Ensuring smooth internal transport.
- Optimisation of the production control strategy: Identifying the factors influencing material flow and factory structure.
When it comes to operational implementation, we do not stop at theoretical PowerPoint concepts, but work in partnership to support the physical realisation directly on the factory floor. Using modern 3D material flow simulations and data-driven planning tools, we precisely validate all developed layouts and processes before any construction work or investments are carried out. In this way, we ensure the new structures are seamlessly integrated into day-to-day plant operations and guarantee measurable efficiency gains from the very first day of operation.
7 phases to a future-proof factory
Successful factory layout planning requires a systematic, data-driven and transparent approach. Drawing on experience from over 50 successful factory planning projects and in line with the VDI 5200 guideline, ebp-consulting has developed a tried-and-tested 7-phase process. This methodological guide guarantees you the highest level of planning reliability and on-time delivery – from the initial concept through to operational implementation.
Phase 1: Defining Objectives
Every successful project begins with a clear strategic direction. In the first phase, we work with you to define the overarching objectives, future growth scenarios and the economic framework for your factory planning.
Phase 2: Planning Basis
Sound planning requires reliable data. We collect and analyse all relevant current data, production capacities, product range structures and structural constraints. This phase forms the fundamental basis for all subsequent calculations and layouts.
Phase 3: Structural, Process and System Planning
Here, we design the holistic architecture of your value creation. We define the ideal material and information flows and coordinate production, logistics and infrastructure processes in such a way that lead times are drastically minimised and waste is eliminated.
Phase 4: Definition of Modules & Space Allocation
In this critical step, we zoom in on the details: we identify all necessary operational modules (such as machine stations, buffer zones and access routes) and determine a robust, detailed space allocation plan. In this way, we ensure that the actual space requirements correspond exactly to the available capacity at the greenfield or brownfield site.
Phase 5: Ideal and Real-World Layout Planning
The heart of our engineering work: first, we arrange the functional areas without restrictions to create a perfect ideal layout. We then translate this concept into reality by incorporating structural constraints (such as column grids or fire safety regulations). Using state-of-the-art tools such as VisTable, we visualise the preferred version of the real-world layout for you in a transparent and tangible way.
Phase 6: Investment Planning
As a manufacturer-independent consultancy, we are solely committed to your measurable ROI. We calculate the necessary investments for the structural and technical implementation of the preferred layout variant, thereby ensuring absolute budget transparency prior to the final decision-making process.
Phase 7: Timetable & Implementation
The conceptual planning phase concludes with a detailed timetable. Integrated quality gates ensure that all milestones relating to costs, deadlines and quality are met precisely. We do not stop at mere PowerPoint concepts: our experts work alongside you as partners – complete with hard hats and safety boots – right through to successful commissioning in day-to-day operations.
