45K m²
Optimized factory layout (reduced from 52 Km²)
Restarting a Greenfield Factory Planning Project
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.
Industry: Industrial Manufacturing
Service: Factory Planning
Service: Manufacturing
Service: 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.
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Facing Similar Greenfield Planning Challenges
- Starting construction while still needing to optimize factory layout.
- Managing multiple planning streams with limited time and high complexity.
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