Factory planning at the state-of-the-art

Factory planning from concept to detailed layout

Fit for the future with factory planning

The initiation of factory planning, also known as plant structure planning or factory design, is usually due to the fact that the factory no longer meets the requirements placed on it. This can apply to the replanning, rescheduling or expansion of a factory. The following are reasons for a factory planning project:

  • low profitability
  • low capacities
  • changes in the product portfolio
  • changed legal situation
  • new corporate strategy

Factory planning according to VDI 5200

When planning and building a new factory, the needs and requirements of the individual company must be taken into account as early as the planning phase. This is the only way to set the course for efficient operation. Bross & Partner accompanies you from the concept to the detailed layout during factory planning and relies on close cooperation with your company. For an optimal result, we proceed in factory planning according to the guideline VDI 5200. In this planning procedure, the requirements and basics of factory planning are defined, planned and implemented in seven phases as shown in the following figure.

factory planning procedures vdi 5200
Factory Planning Procedures VDI 5200

Determination of the factory targets and determination of the planning basis

In the target definition, the targets for factory planning are derived from the corporate strategy. These goals are also used to evaluate the concepts. In order for a company to survive in the long term and have a high degree of future robustness, the following goals are important:

  • short material flows & movements
  • high space efficiency
  • attractive working environment
  • high flexibility and adaptability
  • sustainable use of resources and energy-efficient operation

The contents of the basic evaluation in factory planning are analogous to those of the first service phase according to HOAI – the Fee Structure for Architects and Engineers. Accordingly, the basic evaluation is an essential part of the preparation. The goal is to develop a project plan and to collect all necessary information and data as well as to define the production program.

From concept planning to detailed planning

In concept planning, the formulated goals are transformed into a resilient concept. This first requires structuring the enterprise into organisational and functional units. This is followed by the dimensioning of the number of operating resources and employees as well as the floor space. For the dimensioning of indirect areas, we recommend our book “Dimensioning Indirect Areas on the Basis of Fuzzy Data“. To develop the best possible factory layout, it makes sense to determine an ideal layout. Starting from this, real layouts are derived step by step. Finally, the real layouts are compared with the ideal layout and evaluated. According to HOAI, the accompanying phase of factory planning is preliminary planning.

In detailed planning, the best-evaluated real layout is detailed. The first detailing step consists of detailed planning by converting block layouts into millimetre layouts. In addition to the factory building, this also contains information on media and material supply. In addition, all the necessary documents for submitting building and permit applications are compiled. Another extensive part of the factory structure planning consists of the preparation of specifications and tenders for the equipment and trades to be procured. Finally, the costs are determined, which is also part of the parallel service phases according to design planning, approval planning and implementation planning according to HOAI.

The realization of the factory planning and the ramp-up of the factory

In the preparation for realization, offers are obtained on the basis of the specifications. For the purpose of comparability, the offers must be coordinated with the suppliers and the scopes must be adjusted. Only in this way is it possible to award the contract with the best price-performance ratio. Based on the delivery times and the project plan of the factory planning, an implementation plan must now be drawn up. The corresponding service phases of the HOAI are here the preparation and the participation in the awarding of the contract.

In the implementation supervision, the progress of the factory planning and the adherence to the specified deadlines are constantly monitored. In addition, a performance control is to ensure the implementation quality. Appropriate measures are to be initiated if deadlines are not met. Finally, all preparations for the move-in are to be made. Analogous to realization monitoring as part of factory planning, the object monitoring sub-step is carried out in accordance with HOAI.

With the SOP – the Start of Production – the ramp-up supervision takes place after the factory planning, which is to ensure the achievement of the targeted capacity utilization by successively increasing the production load. This is done by fine-tuning production logistics and stabilizing production processes. In addition to the support of the production systems, the object support and documentation is carried out.

Digital planning with tools such as visTABLE®

With our range of services, we address both companies that are planning a complete new factory from scratch as well as companies that want to revise and optimize already existing plants. In addition to layout planning, our experts are also active in production planning, logistics planning and material flow planning. To identify optimization potential in material flow, we rely on state-of-the-art material flow simulation software such as Siemens Tecnomatix Plant Simulation®, Autodesk® and Plavis visTABLE®. By using state-of-the-art tools, we are able to take into account all the details of factory planning and tailor them to your needs.

Factory planning as the basis for a smart factory

You want to make your company fit for the future? Then rely on our offer for factory planning. We reliably accompany you on the way to a smart factory and plan the precise networking of various machines and processes. In the process, we help you select the right information and communication technology. In order to remain competitive in the long term, the conversion to Industry 4.0 is considered inevitable on the one hand, but is also one of the greatest challenges on the other. It is therefore all the more important that this is planned precisely and with foresight right from the start.

Do you need advice on restructuring or redesigning your factory?

Contact our factory planning experts for a free & no obligation consultation.

Your contact person

Dr. Florian Bross

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