Benchmarks & Client Cases

New Plant Design

The Challenge

new-plant-design-project-management

Problem


• 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

 new-plant-design-layout

• 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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