// Projects / Site and Factory Planning

Detailed planning and tendering of the logistics areas for the site expansion of the electronics production of a smart home manufacturer

After the successful rough planning and conceptual design of the logistics areas and processes, the implementation experts of BLSG consistently accompanied the next phase of the site expansion of the electronics production of a household appliance manufacturer.
The planning of the functional areas and processes for storage and transport in coordination with the production, construction and logistics departments are prerequisites for the successful implementation of the site expansion. The integration of the new logistics and production areas and processes into the ongoing operations and a multiplication of the production volume within the next few years represent a particular challenge.
Based on a comprehensive analysis, the logistics areas and processes were defined, dimensioned and integrated into the planned overall layout. The BLSG experts specified requirements for the storage and transport technology in order to be able to optimally store and transport raw materials and finished goods and accompanied the tender and supplier selection.
The result: A detailed layout of all logistics areas, the definition of all logistics processes in the warehouse and in production in SAP EWM, and a complete specification for the tender of all required hardware and software form the basis for the realization of the successful site expansion.

Validation and generation of a tender document for an automated small parts warehouse (AS/RS)

The introduction of automated solutions in logistics bring quick measurable results and often have a quick ROI. During our project at a construction equipment manufacturer, we investigated the potential use of an Automated Small Parts Warehouse (AS/RS). In addition to benefits such as a lower error rate and improved space efficiency, the AS/RS offers the company the advantage of a much more efficient order picking setup, reducing inventory and space requirements on the assembly line. As implementation consultants, we assisted our client in this process through all the important steps involved in evaluating and implementing an AS/RS. Starting with the determination of the needed storage space and dynamics, the conception of the storage and retrieval stacks as well as the corresponding repacking area, up to the business case calculation and the creation of presentation material as a basis for a board decision. Following the board`s go-ahead, we worked together with the team on site to draw up a tender document and assisted in the selection of suppliers and the evaluation of bids.

Logistics concepts in the beverage industry

Logistics planning in the beverage industry brings special challenges. The coordination of the very high material flows (up to 500 PAL/h) in such a concept is the central factor. Another special feature are the seasonally strongly fluctuating production figures, as well as the management of empties.
Together with our customer, we have developed and evaluated several innovative and future-oriented logistics concepts to prepare the customer for the coming decade.
Key points of our concept are the robustness, scalability and process reliability of all operations, which we ensure through the use of AGV, intelligent RFID tracking as well as automated order compilation and loading.

Implementation of SAP S/4 Hana for the production of electric vehicles and batteries

The transformation from combustion engine to the battery-powered electric motor poses major challenges for the automotive industry. In the course of this, numerous new production sites are being built for the manufacture of e-vehicles.

A trend-setting decision in this context is the IT system design of such a new plant. To identify the optimal system, BLSG supported a German premium OEM in the selection of the ERP for production & logistics. In addition to FIT/GAP analyses based on master process lists, various scenarios were evaluated and compared based on specific criteria (e.g. costs, resources, opportunities, risks, etc.).

The final scenario, which is technically feasible and meets the requirements, is based on SAP S4 Hana. The approval process for the budget as well as the required resources was supported by BLSG through various committees up to board level.

Creation of a requirement profile for an adaptable factory

In modern automobile production, factories must constantly be adapted to changing products and technologies. This raises the question of how to design factory structures flexible enough for product changes and at the same time able adjust to changing market and technology conditions. BLSG’s experts drew up requirement profiles and analysed the weak points of factory planning and factory structure. The vision of a versatile factory including suitable implementation strategies was the result.