Intralogistics Planning: processes & logistics

In a globally interconnected logistics landscape, companies face enormous pressure to handle volatile demand and ever-growing product ranges in highly limited spaces whilst conserving resources. Compounding these challenges are the dramatic shortage of skilled workers on the shop floor and the need to migrate existing plant and equipment to highly automated systems without interrupting production. This enormous complexity, arising from structural constraints, IT interfaces and new technologies, quickly overwhelms internal project teams and often leads to costly planning errors or system failures. This is precisely where ebp-consulting comes in, methodically breaking down these structural barriers and using its in-depth expertise to implement bespoke, investment-safe logistics concepts for you.

Space constraints and brownfield integration

Expanding product ranges are forcing companies to make smarter use of existing buildings and to integrate modern conveyor technology into often historically evolved, sub-optimal hall layouts. This modernisation whilst operations continue requires the utmost precision in planning to absolutely avoid costly production downtime or catastrophic spatial conflicts. ebp-consulting addresses this challenge through the targeted use of digital twins and 3D simulations, which virtually validate the modifications and guarantee a seamless retrofit.

Skills Shortage and Pressure to Automate

The severe shortage of operational logistics staff means that the use of automation solutions and robotics has shifted from being merely a driver of efficiency to an existential necessity for plant growth. However, selecting the right technology from a confusing market of suppliers always carries the risk of falling into a costly vendor lock-in due to oversized technology. As a neutral partner, ebp-consulting selects the systems that are precisely suited to your specific business case and manages the tender process in a manner that is entirely manufacturer-independent.

Lack of data transparency and IT disconnects

Efficient intralogistics absolutely requires the seamless, real-time integration of physical material flow with the controlling logistics IT systems, such as WMS, MFR or ERP systems. In practice, opaque stock levels and faulty software interfaces often lead to system failures, search delays and cumbersome warehouse processes after go-live. We conduct an early, data-driven analysis of your system landscape and design end-to-end information flows that maximise your planning reliability and reliably pave the way to the digital factory.

To design future-proof and resilient factory logistics, layout, technology and IT must be perfectly coordinated, like clockwork, during the planning phase. The following six core strategic areas form the foundation of our planning work and are essential to any far-reaching logistics restructuring. Rely on our tried-and-tested best practices, which integrate technical innovations into your factory in a pragmatic and, above all, cost-effective manner.

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Data-driven potential analysis

ebp-consulting structures your master data, stock levels and transaction data down to the smallest detail to precisely identify bottlenecks and inefficiencies in the existing warehouse layout. Use these objective metrics to replace gut feelings with hard facts and to justify well-founded investment decisions to management. From our extensive project experience, we know that only thorough data cleansing using tools such as KNIME or Tableau reveals the true optimisation potential of your intralogistics planning.

Layout Planning and Dimensioning

We design space-optimised warehouse and order-picking structures that minimise lead times and can respond with extreme flexibility to future volume fluctuations. Ensure that, during the planning phase, you always opt for modular grid concepts that allow for gradual expansion without major structural alterations. The engineers at ebp-consulting apply scientific methods from the Fraunhofer Institutes directly to create pragmatic, collision-free CAD layouts for your shop floor.

Technology Scouting and Automation (TCO/ROI)

We compare different solution options – from shuttles and automated small-part warehouses (AKL) through to AMRs and AutoStore – and evaluate them strictly according to performance limits, energy requirements and total cost of ownership. Always tailor the level of automation to your actual product variety, rather than attempting to mechanise every manual picking process in a compulsive and cost-intensive manner. Thanks to our complete manufacturer neutrality, we guarantee you a bespoke technical concept that pays for itself quickly and is by no means oversized.

Material Flow Simulation and Digital Twin

By creating dynamic 3D simulation models, we virtually test load assumptions, automated guided vehicle (AGV) cycle times and stress scenarios before the first physical ground-breaking takes place. This effectively protects you from costly planning errors in material flow and reliably ensures your facility’s performance, even during peak periods. Our consultancy experience consistently demonstrates how such a digital twin wins over stakeholders from the outset through tangible visualisations and makes risks transparent.

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Specification Development and Tender Management

A detailed specification document that clearly sets out all KPIs, availability figures, fire safety requirements and IT interfaces is the only key to successful technical procurement. Do not leave negotiations to chance; instead, secure fair market terms through structured discussions with bidders and rigorous tender evaluations. ebp-consulting provides comprehensive support throughout this tender process and delivers a robust, objective recommendation for the selection of service providers and plant manufacturers.

Ergonomics and workplace design

Even highly automated systems require human input, which is why we design picking and packing workstations in accordance with strict cognitive and physical ergonomic criteria. Make use of planning approaches such as Cardboard Engineering to test picking stations to scale with staff in advance, thereby significantly increasing process reliability. We integrate specialist knowledge from the Fraunhofer network to reduce physical strain and make manual work future-proof through smart assistance systems.

ebp-consulting GmbH provides methodical support for your intralogistics planning, from the initial data analysis through concept development right through to supporting the go-live during ongoing operations. Our scientifically grounded approach breaks down complex automation or construction projects into clearly defined, manageable phases. This enables us to guarantee you maximum transparency, absolute adherence to deadlines and seamless integration of buildings, conveyor systems and the controlling logistics IT.

Systematic Analysis of the Current Situation & Data Modelling

We set ourselves apart from traditional approaches by not only conducting interviews, but also thoroughly cleaning and structuring your operational data sets and converting them into precise material flow diagrams. This data-driven methodology enables us to define the exact state of your intralogistics and to pinpoint bottlenecks with absolute precision, rather than relying on gut feelings. Building on this, we create an objective, mathematically robust quantitative framework as a stable foundation for all subsequent simulation and planning steps.

Concept Development & Technology Selection

In this phase, we develop various technical and layout options, which we evaluate impartially against one another using tools such as 3D simulations and test for their practical suitability. What makes the ebp methodology unique in this regard is our radical independence from manufacturers, as we do not favour our own hardware solutions or receive commissions from plant manufacturers. We evaluate automation technology and software purely on the basis of their technical and economic benefits for your specific business case, using rigorous TCO analyses. In this way, we reliably protect you from poor decisions, oversized systems and the resulting, very costly vendor lock-in.

Detailed Planning & Tender Support

We translate the selected preferred concept into a watertight specification document, which sets out IT, technical and process requirements in detail and unambiguously for the tender market. ebp-consulting structures the entire tender process, facilitates discussions with bidders on an equal footing and conducts an in-depth evaluation of the bids received. This methodologically rigorous process sets our consultancy approach apart, as it relieves you of the commercial complexities and protects you from hidden follow-on costs. It is precisely this combination of technical engineering expertise and commercial negotiating skills that manifests our high value contribution in terms of planning reliability.

Implementation of Intralogistics Planning & Go-Live

We do not simply hand over theoretical plans; instead, we take charge of project management (PMO) right through to turnkey handover directly on the shop floor. Our interdisciplinary team resolves complex interfaces between building construction, intralogistics systems and IT, and reliably ensures the critical ramp-up of the facility. This unwavering focus on the practical realities of implementation – including functional tests and acceptance checks – sets us apart from purely strategic consultants. With ebp-consulting at your side, the go-live of your new intralogistics system will proceed efficiently, smoothly and precisely within the ambitious timeframe.

Put your trust in ebp-consulting as your manufacturer-neutral partner, combining scientifically sound intralogistics planning with uncompromising implementation expertise directly on the shop floor. Whether through an agile strategic quick check, targeted interim management to bridge resource gaps, or as a turnkey end-to-end project – we guarantee you tailor-made, seamless solutions with maximum investment security. Secure our proven hands-on expertise now and launch your project to turn your logistics visions into reality swiftly and effectively.

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