Key points at a glance:
Problem: Factory design is not a simple task – historically evolved structures often suffer from long transport distances, high inventory levels, and rigid layouts that hinder automation, flexible scaling, and realizing existing potential.
Solution: Data-driven factory design tailored to specific requirements. We develop efficient value streams from the very beginning and design the factory layout around ideal processes.
Result: A dynamic, scalable, and flexible plant structure and smart factory with cost efficiency, significantly reduced lead times, and a benefit-driven level of automation.
Benefit: Transparent decision-making confidence through interactive 3D layouts and material flow simulations – long before any renovation or new construction actually happens.
What defines the factory design of the future?
Factory design begins with optimizing value-adding activities through a value stream analysis. How does the material flow? How does information flow from A to B? Where is there waste? How can value creation in production be increased? We develop the right layouts to design optimal processes and value streams and integrate automation technology into them. We rely on our proven step-by-step project approach to do this, meaning your specific needs are met and your factory designed comprehensively.
Value stream analysis and value stream design eliminate waste and unlock potential
Interactive 3D layouts support management decisions by being able to test variants
Automation is not integrated as an end in itself, but based on methodology and with added value
io supported Timpla GmbH in Eberswalde from the concept phase (proof of concept) through detailed planning and tendering to implementation and the successful ramp-up of production and logistics.
io provided comprehensive support to the Würth Group throughout the construction of a new central off-site warehouse across all project phases – from concept planning to successful commissioning, including the use of cross-departmental automated guided vehicle systems.
io developed a value stream-oriented production design for Destilla GmbH as part of the consolidation of several locations and was responsible for the layout design of the future production structure at the Nördlingen site.
Value stream mapping and design
We ensure transparency throughout the product journey – from incoming goods right through their journey to becoming outgoing goods. Bottlenecks, lead times, and waste are identified. The resulting value stream analysis forms the basis for value stream design, in other words, realigning processes and structures.
Interactive concept planning
We develop layout variants based on the value stream in interactive 3D scenarios. Spaces, workflows, and material flows are virtually mapped out and evaluated together with your departments – at absolutely no risk and before a single brick is laid.
Automation concepts
Not every automation project is going to be beneficial. We analyze your production volumes, product variety, and cycle times to determine the economically viable level of automation – with an ROI calculation for every measure taken, from partial automation to Smart Factory.
Our tools for your production
We combine methodical process analysis with state-of-the-art 3D concept planning to design and deliver a highly profitable factory.
Integrated assembly planning
Assembly planning
Automated, flexible, and cost-effective
We streamline assembly processes and enable optimal value creation—from the initial idea all the way to the shop floor.
Economic leverage in factory design
Productivity
Space efficiency
A layout consistently aligned with the value stream significantly increases your output volume on the same size of floor area.
Shorter lead times
Lean production
We accelerate the product cycle by eliminating downtime and material flow backflows.
FAQ
What exactly happens during value stream mapping? ×
We map the actual product and material flow directly within your production facility – from incoming goods to shipping. We measure processing, transport, and idle times and identify non-value-adding activities. The analysis is the definitive basis for a process and value stream design in which waste is consistently eliminated and flow-oriented structures developed.
We are planning a retrofit (brownfield). Can this be done without stopping production? ×
How does interactive 3D concept planning help me? ×
We build your future plant virtually as a digital twin instead of static 2D plans. You can see in real time how a change (e.g., a new AGV system or a different machine layout) affects space requirements, material flow, and investment costs. This provides absolute decision-making confidence for management.
Is building design (architecture) also part of factory design? ×
Factory design (the layout of processes and logistics) comes before architecture. We deliver optimal solutions through integrated design between architecture and factory design. Since io is also a lead consultant, we can seamlessly offer you the complete architectural and MEP planning from a single source following factory design.
How do you determine the right level of automation for our factory? ×
Not everything that could be done through technology makes economic sense. We analyze your production volumes, product variety, and cycle times in ROI calculations. It often turns out that a highly flexible, semi-automated system is more economical and resilient to market fluctuations than a rigid, fully automated system.
