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Production Design

We design new production systems worldwide and optimize existing productions.

How can I ensure competitiveness and sustainability of production in a dynamic environment?

Market requirements to which companies have to react to change rapidly today.

Not only start-ups are faced with the challenge of bringing new products to market as quickly as possible. In order to shorten the time-to-market, production must already be planned and set up while the development of the product is not yet completed. How can production be designed under high time pressure and fuzzy information? By parallelizing processes and using versatile production systems.
From the building to the system concept, from greenfield to brownfield optimization: with our scientifically based modular method, we plan your production systems and support you in the production-oriented design of your product portfolio.

Key questions

How do I set up the production of a new product if the product is still in development?

How do I design a versatile production system that can be flexibly adapted to new requirements?

How do I accelerate my production processes and where can I start to make my processes even more efficient?

What is the optimal material and value flow for my production?

How do I minimize the integration losses of new products or technologies in my production system?

Reference projects

Client
OEM (Germany)
Target
  • Planning of a low-investment assembly concept for a small series production
  • Ensuring a production output of 10,000 vehicles/year (1-shift)
  • Achievement of a fast reacting change management in the assembly
Approach
  • Definition of all relevant requirements (e.g. workplace guidelines) and target criteria
  • Development and evaluation of different planning scenarios
  • Creation of the 2D block layout, optimized according to material flow and assembly concept
  • Detailing of the block layout in cooperation with the client
  • Conversion to 3D CAD layout and validation using virtual reality in Autodesk Inventor and BIM 360 Cloud
Achievement
  • Detailed 2D CAD and 3D layouts of the production, logistics and indirect areas as a basis for implementation planning
  • Reduction of planning time parallel to product development until validation milestone by 30%
Client
Start-up Urban Air Mobility (Germany)
Target
  • Conception and qualification of a scalable battery production (up to 10.000 pieces/year)
Approach
  • Analysis of the product design and definition of requirements
  • Capacity and layout planning to synchronize the individual production processes
  • Expansion and qualification of the safety concept for battery production and storage
  • Evaluation of technical, quality and time risks
  • Derivation of scenarios for tripling production capacity and identify limiting factors
  • Make-or-buy analysis considering the identified scenarios and risks as well as strategic and economic factors
Achievement
  • Qualified battery production concept for the start of series production
  • Expansion scenarios to triple battery production
Client
OEM (Germany)
Target
  • Planning of a low-investment assembly concept for small batch production
  • Ensuring a production output of 10,000 vehicles / year (1 shift)
  • Achieving a change management in assembly with quickly react
Approach
  • Establishment of an integrated digital planning approach for the assembly processes
  • Conception and description of the assembly processes via SE teams using a digital planning tool (MPM-Link) incl. maturity level management
  • Creation of assembly instructions and priority sequence diagrams
  • Line synchronization of 28 assembly stations in consideration of all dependencies in the assembly process
Achievement
  • Digital integrated and fully described assembly process for the entire vehicle, including all relevant data and complete line synchronization
Client
Premium-OEM (Germany)
Target
  • Improvement of the ramp-up management by optimizing the logistics planning in the pre-series
  • Create data transparency, accuracy and integrity at ramp-up
Approach
  • Visualization of the current logistics situation and associated IT landscape
  • Development of a logistic end-to-end process in the ramp-up management
  • Development of a tool for the consolidation of logistics data including ERP connection (rolling target-performance comparison as well as launch readiness tracking)
  • Project management support for the transfer of the developed tool for direct mapping in ERP
  • Support during the test phase for the optimization and implementation of the new database as well as training for the established use of the tool functionalities
Achievement
  • Management of 22 pre-series phases with a simultaneous increase in production volume of 40% within one year
  • Supervision of transfer of the tool into the existing productive systems and enabling the customer to continue using it independently

Whitepaper

Fast Lane Factory

Companies operating in a highly competitive environment face the challenge of planning their factories more efficiently in order to reduce their time-to-market.

Four innovative planning modules enable accelerated factory construction by integrating modern planning methods, optimized construction processes, and innovative ramp-up concepts.

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Daniel Ott
Principal
LinkedIn
Dennis Andrecht
Principal
LinkedIn
Alexander Pies
Practice Lead Production Design
LinkedIn

Contact

Are you interested in a project or have questions about our services? We look forward to hearing from you!

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Digital Products & Services

Development of digital solutions for your products to exceed the expectations of your customers today and tomorrow.

Production Strategy

Development of forward-looking and holistic production strategies – taking all relevant factors into account.

Production Design

Global design of new production systems and optimization of existing ones.

Integrated Product & Process Development

By bridging product and process development, we enable the realization of innovative products in the shortest possible time.

Digital
Manufac­turing

Transformation of product and process landscapes through the targeted use of innovative digitalization opportunities.

Sustainable Industrial Transform­ation

Profitability and sustainability are not contradictory – they can be purposefully combined.