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General and Detailed Planning

Your path to an optimized real image.

T&O Industrial Excellence guides you to your optimized real image in 8 steps. The services differ between ideal development (steps 1 to 4, without reference ot buildings and/or land) and real development (steps 5 to 8, with reference to buildings and/or land), which are applied depending on requirements.

Ideal Image Development

without reference to buildings and/or land

Step 1: Inventory & current analysis

Value stream analysis, production matrix, material flow analysis, key figure benchmark

Step 2: Clarification of strategic framework

Performance plan, product portfolio

Step 3: Potential definition and optimization processes, spatial arrangement

Value stream design, lean logistics, timing (customer cycle), automation, I4.0

Step 4: Determine needs & develop ideal image

Dimensioning of areas directly & indirectly, systems, employees, logistics, ideal block layout in CAD

Real Image Development

with reference to buildings and/or land

Step 5: Develop master plan studios

Variant studies in CAD with reference to buildings and/or land

Step 6: Evaluation utility analysis

Utility analysis

Step 7: Develop real image and determine costs

Block layout in CAD, cost list

Step 8: Basis for decision

Presentation of results, if necessary, amortization considerations

Procedure of Real Formation

Concept Study

  • Fundamental Structuring of the Site
  • Functional Areas
  • Central Traffic and Material Flow Axes
  • Access and Expansion Axes

Variant Representation

  • Development of Site Occupancy Variants
  • Variant Evaluation Process (utility analytical/economic)
  • Determination of the Preferred Variant
     

Optimal Variant

  • Elaboration of the Preferred Variant
  • Definition of the Building Structure
  • Traffic and Material Flow Concept
  • Implementation Roadmap
  • Investment Requirements

Based on many development variants, create an overview – promote the economic use of valuable areas.

The Goals of Manufacturing Segmentation

The segmentation aims to combine the cost and productivity advantages of flow production with the high flexibility of job shop production.
 

The manufacturing process is divided into several autonomous functional groups or manufacturing segments. In such a segment, several steps of the production process are reflected.

The influencing factors for the optimal design of workplaces

The goal is to achieve the same cycle times for workplaces and to be able to establish them in the production flow without buffer storage.

It is defined through the work instructions which work contents are assigned to the individual workplaces.
Each workplace is set up according to the process steps to be performed. The process steps at the workplaces then determine the micro-material flow and the workplace layout.

Our proven analyses of material handling

Handling analyses help to analyze and depict how often material is "touched" or moved. The goal of layout planning must be to move the material as little as possible and to store it in buffer storage. The handling analysis supports or complements the value stream analyses of the material flows.
 

 

 

The Development of the Optimal Logistics Concept

The 8 Steps to the Ideal Shop Floor Logistics Concept

1. Identifying the Material Supply Processes

2. Identifying Wastes

3. Jointly Defining Requirements

4. Defining Inventory for the Shop Floor
 

5. Defining Future Material Supply Rules

6. Determining Quantities, Containers, Transport, and Storage Means
 

7. Considering and Optimizing Side and Supply Processes

8. Sustainability: Documenting and Visualizing Shop Floor Logistics, Integrating Key Figures into Shop Floor Management

The Arrangement of Workstations and Buffers Follows Our Fundamental Understanding

Goal Orientation, Success Positions and Core Competencies, High Depth of Manufacturing, Reorientation Towards Sales Control, Reduction of Complexity, and Building Flexible Process Organizations Shape the Areas. Process-oriented Manufacturing Areas with Complete Processing as well as Transparent and Manageable Macro Material Flows, Decoupling of Human and Machine Capacity.

Production Design and Material Flow Significantly Determine the Structure. The Arrangement of Workstations is Made Considering the Manufacturing and Material Flow. The Right Arrangement of Workstations in the Layout Favors the Reduction of Inventories (Buffers). Necessary Material Buffers Can Be Sensibly Defined.

Visual Management

We Consider Marking and Signage as Part of Visual Management.
Markings are Absolutely Necessary for Optimal Workflows and Additionally Support Keeping Production Sites Neat and Tidy. Floor Markings Serve to Visualize Storage Areas or to Define Boundaries of Areas. Storage Areas Are Not Only to Be Used for Placing Parts but Should Also Support the Factory Structure as Self-regulating Part Places.

These Are Essential Elements of a Comprehensive Visual Management.