Services assembly planning

Assembly planning

Assembly planning in the manufacturing industry

Assembly planning includes the strategic and careful development of manufacturing processes as well as the design and optimization of production facilities. At its core, it’s about optimizing operations, increasing productivity, and ensuring the efficient use of resources. By accurately analyzing production requirements, workflows, and desired outcomes, we develop comprehensive plans that synchronize all elements of the manufacturing process.

In the dynamic landscape of the manufacturing industry, process and plant design plays a crucial role in competitiveness and sustainability. Our work not only has an impact on the internal operations of a company, but also extends to the broader economic context. Efficient processes and well-designed equipment contribute to increased productivity, cost savings and improved quality, thus promoting economic growth and profitability.

In addition, the benefits of our perspective go beyond the financial realm. By leveraging our expertise in process and plant design, our customers experience improved operational efficiency, reduced waste, and improved product quality. We help them optimize their production systems, effectively align their resources, and eliminate bottlenecks, resulting in smoother operations and increased customer satisfaction.

In addition, we emphasize the integration of advanced technologies and innovative practices in our approach to process and plant design. From the use of automation and robotics to the implementation of data-driven analytics, we strive to harness the potential of Industry 4.0 and set new standards in terms of efficiency and flexibility.

The world of process and plant design in the manufacturing industry is an area of meticulous optimization, strategic decision-making, and technological innovation. It forms the basis for the efficient use of resources, the achievement of economic prosperity and the fulfillment of customer requirements.

Process planning

Optimization of production processes for maximum efficiency and quality

Production process planning deals with the systematic planning and optimization of manufacturing processes in production. As a team of experts in factory and production planning, we mainly provide support in the following services:

  • Station analysis (MTM, Refa): We analyze the workstations and processes using methods such as MTM (Methods-Time Measurement) and Refa (Work Design). In this way, we determine the optimal expenditure of time and the ergonomic design of the workstations.
  • Balancing: We plan the timing of work processes in production to ensure a smooth and synchronized process. This enables optimal utilization of resources and efficient production.

  • Assembly priority graphs: We create assembly priority graphs that visualize the sequence of assembly steps and enable a clear structuring of the assembly processes. This ensures efficient and logical execution of the assembly work.

  • Layout development and integration: We develop and integrate optimized layouts for production facilities to ensure a smooth flow of materials and information as well as ergonomic working conditions. In doing so, we take into account factors such as space requirements, workflows and safety aspects. In doing so, we take into account factors such as space requirements, workflows and safety aspects.

  • Headcount (HC) accounting: We carry out an HC calculation (workplace cost accounting) in order to analyze and optimize the costs of jobs in production. In this way, potential savings are identified and measures to increase efficiency are derived.

  • CIP (Continuous Improvement Process): We support companies in the implementation of a continuous improvement process in order to continuously analyze production processes, identify optimization potentials and implement measures for continuous improvement.

Through our technical expertise and comprehensive knowledge in production process planning, we support companies in making their manufacturing processes efficient. With methods such as station analysis, balancing, assembly priority graphs, layout development, headcount calculation and CIP, we create an optimal production environment and increase the efficiency and quality of production.

Industrial engineering

Achieving the optimum with a system

The field of “Industrial Engineering in Production Planning” includes a variety of methods and approaches for optimizing production processes. Our team mainly focuses on the following services:

  • Production control: We support the efficient planning and control of production processes in order to ensure optimal use of resources and on-time production.

  • Value stream mapping and design: We perform value stream mapping to analyze the flow of materials and information in production and identify weak points. Based on the results, we develop optimized value stream designs to improve flow and reduce waste.

  • Line balancing: We optimize the workload distribution on the production lines in order to achieve an even utilization of employees and machines. This minimizes bottlenecks and ensures efficient production.

  • Waste analysis: We analyze the processes and identify waste in the form of overproduction, waiting times, unnecessary movements and other inefficient activities. On this basis, we develop measures to reduce waste and continuous improvement.

  • Workplace design: We design workplaces ergonomically and efficiently to improve working conditions, increase employee satisfaction and reduce errors. Through an optimal arrangement of tools, materials and work processes, we create ergonomic and productive working environments.

  • Ergonomie: We take ergonomic aspects into account in the design of workplaces, machines and production processes to ensure the health and safety of employees. We analyze and optimize working conditions to minimize ergonomic risks and increase productivity.

  • Labor Calculation: We analyze the personnel requirements and calculate the required number of workers in production. In doing so, we take into account factors such as working hours, utilization, skills and production volume to ensure efficient workforce planning.

  • User-specific process modules: We develop tailor-made process modules that are specially tailored to the customer’s requirements. These building blocks facilitate and standardize workflows and contribute to increasing efficiency.

  • Data aggregation, data cards: We support the aggregation of production data and create data maps that provide a quick and clear overview of relevant information such as quantities, material consumption and processing times. This enables efficient planning and control of production.

  • Planned time catalogs: We create and maintain extensive planned time catalogs that contain standardized time specifications for various work steps and activities. These catalogs serve as the basis for working time estimation, resource planning and the calculation of production orders.

  • Calculation data: We support the collection and preparation of calculation data for production planning. This involves cost analysis, the determination of material and personnel costs as well as the evaluation of production processes with regard to their profitability.

  • Reduction of assembly times through product optimization: We analyze the assembly processes and identify opportunities to reduce assembly times through product optimization. By designing products with simplified assembly and the use of intelligent assembly aids, we contribute to increasing efficiency and saving costs.

Through our expertise in the field of industrial engineering in production planning, we support companies in making their production processes efficient. Using methods such as production control, value stream mapping, line balancing, waste analysis, workplace design and ergonomics, we create optimized production environments, improve production efficiency and quality, and increase employee satisfaction.

Conveyor technology & equipment planning

Optimization for smooth material flow and high productivity

The field of “Conveyor Technology and Equipment Planning” includes the development and design of conveyor technology and equipment for efficient production processes. Our main services in this area include:

  • Concept planning for conveyor technology and equipment: We create comprehensive concepts for conveyor technology and the required equipment in production. In doing so, we take into account the specific requirements of the production process and develop tailor-made solutions for the material flow.

  • Process and plant planning: We seamlessly integrate the conveyor technology and equipment into the entire process and plant planning. This includes coordinating with existing equipment and taking into account process requirements to ensure a smooth flow of materials and efficient production.

  • Planning for handling equipment, tightening technology, assembly systems: We develop detailed plans for handling equipment, screwdriving technology and assembly systems to enable precise and efficient assembly of components. In doing so, we take ergonomic aspects into account and strive for a high level of process reliability.

  • Project management process and equipment planning: We accompany and control the individual phases along the entire planning process – from the first line to the achievement of the required quantity. This ensures that all processes, systems and stakeholders run in harmony and that the various project goals are achieved.

  • Specification/tendering: We support the preparation of specifications and tender documents for conveyor technology and equipment. In doing so, we ensure that all requirements and standards are met and help with the selection of suitable suppliers and service providers.

  • ite coordination: We coordinate the construction site activities related to the installation of the conveyor technology and equipment. In doing so, we monitor progress, ensure that all work is carried out according to specifications, and efficiently solve any problems that arise.

  • Commissioning (ramp-up)/acceptance: We support the commissioning and acceptance of the installed conveyor technology and equipment. Together with the suppliers, we ensure that all systems are working properly, carry out tests/picking, check all quality characteristics and make adjustments to ensure smooth production.

With our expertise in conveyor technology and equipment planning, we support companies in making their production processes efficient. With concept planning, process and plant planning, handling equipment, screwdriving technology, assembly systems, specifications, site coordination and commissioning, we create optimized production environments and ensure a smooth material flow for efficient and high-quality production.

Digital factory & scheduling

Always one step ahead

The field of Digital Factory & Process Planning includes the application of digital technologies to optimize manufacturing processes. Our team mainly focuses on the following services:

  • Planning validation through simulation: We use simulation techniques to virtually analyze the material flow, fault behavior and bottleneck processes in advance. As a result, potential problems can be identified and corrected even before production begins, and planning is secured.
  • Digital representation of assembly processes: We create digital models and visualizations of assembly processes to gain a detailed insight into the processes. This enables us to identify potential for increasing efficiency and make optimizations.

  • Feasibility study: We check the feasibility of planned production processes and ensure that they are technically and logistically feasible. Through digital analysis tools, we can identify bottlenecks and potential problems and develop solutions to ensure smooth production.

  • Scenario formation: We develop various scenarios and variants for production planning and optimization. This enables a comprehensive evaluation of alternatives and supports the decision-making process for the best possible solution.

By using digital methods and tools in the Digital Factory & Scheduling, we support companies in optimizing their manufacturing processes and increasing efficiency. With simulations, digital models, feasibility studies and scenario building, we create a solid basis for efficient and smooth production, even before the physical implementation takes place.