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Designing a Flexible Factory for Complex and Dynamic Production

A global glass manufacturer developing next-generation optical products faced a highly complex production environment with changing product requirements, evolving processes, and brownfield constraints. Partnering with EFESO, the company designed a flexible factory concept with optimized capacity planning, production processes, and value-stream oriented layout to support both current and future product generations.

Industry: Consumer Goods and Luxury

Service: Factory Planning

Service: Manufacturing

Parallaxe

Our Client

A global German glass manufacturer operating worldwide. The project focused on an optical industry production site in Malaysia supporting augmented reality applications.

€2.9 B

Annual revenue

17 K

Employees

Parallaxe

The Challenge

  • The company needed to design and realize a new production environment while managing high complexity, changing requirements, and significant brownfield constraints.
  • Dynamic product development: Ongoing product development resulted in frequent updates to production requirements and planning assumptions.
  • Complex production process: The manufacturing process included approximately 650 process steps requiring detailed capacity and flow planning.
  • Brownfield constraints: The existing building required a factory concept adapted to physical limitations.
  • Capacity bottlenecks: A strong CapEx focus created potential machine bottlenecks and required optimized capacity planning.
  • Transition complexity: New-generation machines needed to be installed while old generation production remained operational.

Real Results Achieved Together

The project enabled the company to establish a flexible and simulation-based factory concept, ensuring production capacity, material flow, and layout decisions were aligned with future requirements.

+650

Production process steps considered in factory planning

Gen1 & Gen2

Product generations supported through a designed mass production process

Transformation Impact

  • Established a parametrizable capacity planning model including static and dynamic production effects.
  • Designed a flexible factory layout supporting evolving production requirements.
  • Improved transparency through dynamic simulation of capacity, material flow, buffers, and lead times.
  • Enabled informed factory realization decisions through data-driven planning and verification.
Parallaxe

Our Approach

EFESO supported the factory planning and realization by combining production process design, capacity modeling, layout planning, and simulation.

  • Static & dynamic capacity planning considering different scenarios ensured the identification of required machine quantities at an early stage
  • Set-up of frequent communication structure between local operations and production planning to verify planning bases and align capacity targets
  • Development of modular planning tools increase efficiency in dealing with constant iterations
  • Dynamic factory capacity simulation allowed to verify and adjust capacity plan, calculated carrier and buffer concepts as well as required and resulting lead times
  • Mass production process design and layout visualization based on 3D models
  • A phase control system (PCS) based risk mgmt. allowed for timely risk anticipation and mitigation
  • Introduction of a project governance to efficiently coordinate workload

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Facing Similar Factory Planning Challenges

  • Managing complex production environments with changing product requirements.
  • Designing new factories or optimizing brownfield sites under capacity constraints.
  • Looking to validate production concepts through data-driven simulation and planning.
  • Seeking flexible layouts that support future growth and operational agility.
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