Factory Planning, General Planning
Defence
Holistic Factory Planning for a New State-of-the-Art Battery Factory
Concept Design:
The backbone of your factory
Highly efficient or maximally adaptable? This is just one possible conflict of objectives that can arise when planning a new factory. In practice, there is frequently no straightforward answer to the numerous complex questions that need to be addressed at the outset of concept design. The objective is to achieve the optimal harmonization of all requirements within the overall system.
The key anchor points of your factory are defined during concept design. The development of quantities, the targeted product variance, the technology used and the underlying production principles are analyzed multidimensionally. The decisions made will form the basis for all subsequent planning phases. It is therefore recommended that an adequate period of time be allowed for the development of the factory concept in order to minimize the number of feedback loops and instances of redundancy due to changes in planning assumptions. Furthermore, the conclusion of the concept phase often marks the first significant decision point in the project, making it a unique opportunity that must be prepared for with the necessary care and attention.
Proven approach to concept design
The application of proven procedural concepts, such as VDI 5200, provides a valuable framework for effective planning. Nevertheless, each project is unique, and we consider this when developing the most appropriate approach for your particular needs. Milestones in the schedule that are already specified at the start of the project or above-average time-intensive procurement processes can, for example, justify deviations from the standard procedure. Essential components of any concept design are the structuring of the factory, the dimensioning of the functional areas in the individual level of detail and the development and evaluation of different concept layout variants. Our roots in discrete manufacturing have shaped our approach to concept design, which incorporates material flow as a fundamental element.
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Factory aligned with corporate strategy
The first step is to derive the factory's alignment from the corporate strategy. This results in a unique or hybrid type pattern for the factory. Based on this, objectives are operationalized, requirements are derived and planning premises are defined in order to establish the basic framework for planning. In addition to the production program, parts lists, work schedules and plant-related key figures, the logistical master data in particular are important input variables for developing a material flow-oriented factory concept. In the event that the necessary data is not yet available in the desired scope or quality at the time of the enquiry, we will provide you with suitable tools for the initial survey or use our experience from a large number of projects to make realistic assumptions together.
Combining customer knowledge and methodological expertise
A meaningful database paves the way for factory design planning. The structuring phase is fundamental to the operation of the factory and is carried out on an individual basis. In collaboration with our expert team, we identify the key segments of the overall system based on defined criteria. It is crucial at this stage to leverage our customers' in-depth understanding of the product, process and technology specifics, coupled with our methodological proficiency and the insights gleaned from analogous projects. Once the structure and the previously prepared data basis have been determined, the prerequisites are in place for dimensioning the defined functional areas. As part of the planning process, the functional areas are quantified by deriving the required space based on the available data.
Dimensioning functional areas with a view to the future
In addition to future-oriented dimensioning of the manufacturing and assembly areas, it is essential to allocate sufficient space for the necessary production supplies and disposal. To achieve this, it is essential to consider the fundamental aspects of production logistics and warehouse design as part of the concept design process. Realistic dimensioning of the factory can only be achieved by considering these functions simultaneously. Furthermore, the factory concept should include the provision of peripherals for machines and systems, pathways, production-related offices, social areas and outdoor facilities from the outset. Typically, a calculated area derivation based on experience and standard values is sufficient for the areas mentioned in this planning phase before the final area dimensions are fixed as part of the detailed planning.
Freedom of design in the concept design phase
Once the dimensioning of all the required functional areas have been established, the next step is to move on to the creative aspect of concept design. We develop different layout variants in joint workshops with experts from all functional areas. Our project experience demonstrates the continued importance of personal interaction at this stage. As a result, we typically conduct the layout workshops on-site at your premises in an interactive, cooperative manner. Subsequently, the layout variants developed are processed and further planning iterations are run through.
Establish interface to object planning
The decision of whether to establish the first interface to property planning during the concept design phase should be made on a case-by-case basis, depending on the degree of involvement of production vis-a-vis the building. Using BIM methodology, we are promoting an integrated project approach that enables the exchange of existing information at the individual entry point of property planning.
Select preferred concept design
After the iterative development of several layout variants, the selection of the preferred variant based on defined criteria is imminent. Economic aspects such as investment and operational costs are just as important as the efficiency of the material flow, which always plays a key role in our assessments. In addition, other factors such as adaptability, flexibility, robustness, resilience and sustainability are included in the assessment in accordance with the factory's alignment defined at the start of the project. We employ utility analyses and related methods to provide an objective assessment of all criteria.
Factory planning initilizes BIM methodology
In accordance with the 'inside out' planning principle, it is evident that the BIM methodology should be initiated by the factory planning. To avoid unnecessary redundancies when establishing system consistency at a later stage, we have set up the factory planning in a BIM-compatible format as early as the concept phase. From the outset of the planning process, we adopt a spatial structure-based approach attribute the spatial requirements that define the building directly in the model.
Simon Vehof
Business Development Manager
Matthias Göke
Managing Partner
Alexandra Kuhns // Senior Manager - Factory Planning