Intralogistics concept | Automotive



Company size

about 9,700 employees

Project duration

9 Months


40,000 m²



Our customer is a specialist for innovative, premium lighting systems and electronics. As systems supplier, they are one of the world’s leading strategic partner for developing and producing premium lighting systems and electronics modules for the automotive industry.


Development of a holistic intralogistics concept with focus on the integration of a planned extension (40,000 m²) into the existing factory structure. Evaluation of the future performance of the internal logistics processes:

  • Analysis of actual in-house transport effort to fulfil production demand based on current production schedule
  • Assessment of the actual intralogistics performance based on the daily required operator and material handlers (FTE)
  • Support of ZKW expansion planning team with a focus on material flow optimisation and storage capacity planning
  • Development of the future shopfloor space allocation based on the projected production program and sales plan (+4 years)
  • Calculation of the capital budget for the defined intralogistics concept and quantified evaluation of improvements (> 30%)
  • Design of a forecast tool for a dynamic calculation of required warehouse capacity (bin) and tugger train performance