Benchmarks & Client Cases

New Plant Design

The Challenge



• Very large investment in a New Plant (9M€ Capex)

• Very long Payback time (7 years)

• Investment on hold

Root Causes

• New Plant Design was very Expensive

• Traditional Supply Chain Design Principles

• Too much waste designed in

The Solution


• Value Stream Design: Develop the entire value chain, aligned with the plant's vision and Lean Principles

• Plant Layout Design: Reduction of waste in logistics, processes and communication circuit

• 8 layouts developed and evaluated against previously identified muda

• Direct link between process and packaging

The Results

Lead Time reduced by 2 days (-10%).

Total Movement Distance and Total Distance Travelled reduced by 1km (-20%).

Capex reduced to 7,9 million € (-12%).

Payback period reduced to 3.5 Years.

Optimal Layout increased Capacity by 25% without the need to increase the size of the finished goods warehouse.

Optimal Layout reduced Handling.

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