Client Situation

A manufacturer of machined aluminium components for the aerospace industry struggled with profitability outside peak market cycles. The factory operated in a high-salary region, relied on aging and inefficient machinery, and had a complex material flow that increased costs and reduced competitiveness. To secure the long-term viability of the site, the company needed a modernized plant layout, a future-oriented machinery concept, and significantly improved flow efficiency.

Objective

Develop a new layout and machinery portfolio that would:

• Enable higher volumes within the existing building footprint
• Improve material flow and reduce waste
• Increase efficiency and quality
• Modernize the technological base with next-generation machining solutions

Approach & Implementation

1. Cross-Functional Diagnostic Phase

A dedicated project team was established to analyze the current situation:

• Mapping of the full material flow
• Assessment of machine condition, utilization, reliability, and capability
• Profitability review of the entire product portfolio

Products that were unprofitable, non-strategic, or required excessive manual work were identified and removed from the future manufacturing scope.

2. Future Technology & Machinery Concept

To define the technological direction:

• A structured study with major machinery suppliers was conducted
• Future machining technologies and automation options were evaluated
• A target concept for next-generation equipment was developed

In several workshops, machines to be removed, replaced, or newly acquired were identified. This created the foundation for a modern, capability-driven machine portfolio.

3. Plant Layout & Flow Optimization

Based on the new machinery concept:

• A redesigned factory layout was developed
• Material flow was simplified and aligned with Lean principles
• Automation concepts were integrated to reduce manual handling
• Space utilization was optimized to accommodate increased production volumes within the existing buildings
  

4. Investment & Implementation Roadmap

A comprehensive plan covering investments, timeline, and organizational adjustments was created.
This roadmap ensured a structured modernization process with minimal disruption to ongoing operations.

Outcome

• Clear modernization strategy for machines, layout, and automation
• Improved material flow and future-proof factory structure
• Reduced labor intensity and improved competitiveness in a high-salary environment
• Investment and implementation plan approved and ready for execution