Factory reorganisation

Flexibility as an answer to the VUCA World

Volatility, uncertainty, complexity & ambiguity, in short VUCA. These qualities characterise today's business environment. Responses to the accompanying dynamics are provided by flexible and agile reaction mechanisms. Although strategic planning in periods of three to five years still serves as an orientation, but it must be possible to adapt quickly to changes in circumstances, especially in the operational context

Against this background, our approach of systemic factory reorganisation pursues the goal of including all relevant buildings and functions with regard to a cost-optimised and structured space allocation and dimensioning. The production logistics flows and the associated costs are the focus of the analysis and evaluation. This approach has enabled us to significantly reduce operating costs in a large number of reorganisation projects. Already in an early project phase, we focus on the feasibility with regard to investment costs, construction-relevant restrictions as well as compliance with time constraints. 

Together with our clients, we have made the experience that the combination of changed planning premises and historically grown structures can lead to significant losses in value over time. Below are selected examples of initiating changes with a current relevance:

  • Automotive - social sustainability awareness, politically set incentive mechanisms (demand side) and sanctions for non-compliance with targets (supply side) promote the market for electromobility, resulting in elementary changes in the product portfolio of the automobile manufacturers, which in turn necessitate adjustments on the part of suppliers and other stakeholders
  • Mechanical & plant engineering - increasingly customer-specific production programmes require a high degree of flexibility with effects on batch sizes and inventories in production as well as the necessity of short-cycle adjustments to the production layout
  • Aeropspace - the "A380 demise" is often perceived as an indication of a paradigm shift within the aerospace industry. Triggered by a change in passenger behaviour, the industry has been concerned for some time with the continued use of wide-body aircraft for long-haul flights. The discontinuation of production of the A380 by 2021, triggered by reduced order volumes, will have a significant impact on production processes in the short and medium term.

In order to ensure economically efficient factory operation in the long term, even under changing conditions, we are promoting a systemic approach to the reorganisation of production facilities. In contrast to classical measures to increase efficiency, we unterstand the factory as an interdependent system. Our approach is determined by a holistic analysis that takes any interdependencies into account.

Our approach is based on four levels, which we consider in the overall systemic context in order to achieve the optimum result.

(1) Consideration of the area and building structure

(2) Consideration of the material flow structure within the factory

(3) Consideration of the production logistical processes

(4) Assessment of operational costs and future performance

In the sense of a customer-centric further development, we are currently working intensively on the transfer of our initial data acquisition into a tool-based application. For our customers we will offer layout adjustments and related performance evaluations as a recurring review process in the future.

Let us understand your VUCA world together and get the maximum efficiency out of your facility. We would be happy to explain the detailed procedure based on your challenges and present the benefits to you in a personal meeting!

Your contact person

Matthias Göke

Managing Director Metroplan Production Management GmbH
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+49 40 20 000 768
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