45K m²
Optimized factory layout (reduced from 52K m²)
Restarting a Greenfield Factory Planning Process
A leading electrotechnical manufacturer needed to rapidly redesign the layout and concept of a new multi-story greenfield factory in the Middle East. EFESO supported the client in reassessing the full building, logistics; enabling fast, data-driven decisions and laid the foundation for an optimized production start.
Industrial Manufacturing
Factory Planning
Manufacturing
Smart Factory
Our Client
A multinational electrotechnical manufacturer operating across the Middle East, Asia, Africa, and Europe. The company produces a wide range of specialized electronic components for applications such as smart cities, energy infrastructure, mobility, and building technology.
The Challenge
The manufacturer sought to expand into a new Middle Eastern market with a multi-story greenfield plant. However, significant planning inconsistencies surfaced just as construction began, requiring a fast and comprehensive redesign.
- Severe time pressure: Excavation had already started, leaving only a small window to adjust the concept.
- Complex production requirements: Multiple value streams, intralogistics flows, and building constraints needed full reassessment.
- Ambitious production expectations: The client aimed for a highly flexible and best-in-class automated environment.
- Need for full alignment: All planning streams—building, logistics, operations—had to be integrated rapidly to prevent costly downstream issues.
Real Results Achieved Together
By leveraging a digital twin of the building and its processes, EFESO and the client rapidly identified optimization opportunities and redefined the entire factory concept within an extremely tight timeframe.
35%
Reduction in overall transport efforts
40%
Reduction in throughput time (from 50 days to 30 days)
Transformation Impact
- Identified and corrected layout inconsistencies before construction
- Optimized material flow, space utilization, and intralogistics design.
- Improved production and logistics processes through scenario-based simulation.
- Created a unified planning framework integrating building, administration, warehousing, and manufacturing.
Our Approach
EFESO deployed a one-stop-shop factory planning approach, bringing together experts in production, logistics, operations, and building design alongside key client stakeholders.
Digital Twin–Driven Redesign
- Created a full building and process simulation to validate all planning scenarios.
- Modeled workplace equipment, warehouse systems, and material flows.
- Identified space and process limitations early in the project.
Integrated Planning Streams
- Evaluated the existing concept for workflows, material handling, and building layout.
- Mapped value streams and intralogistics within the virtual model.
- Defined site requirements, storage systems, and supply concepts.
Operations, Building & Warehouse Excellence Workstreams
- Improved operations footprint and assembly concepts.
- Designed ESG-aligned MEP and modular building solutions.
- Developed CapEx-optimized warehouse technologies and hybrid material distribution systems.
Fast Decision-Making & Stakeholder Alignment
- Ensured rapid decision cycles supported by scenario comparisons.
- Assembled a cross-functional task force of ~12 experts.
- Conducted best-practice tours of European sites to support knowledge transfer.
Related Services
Aging equipment meets rising costs and technology disruption. We transform operations through smart factory integration, predictive maintenance, and workforce capability building.
Facing Similar Greenfield Planning Challenges
- Starting construction while still needing to optimize factory layout.
- Managing multiple planning streams with limited time and high complexity.
- Seeking a digital-twin-enabled approach for fast, aligned, and data-driven decisions.
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