When existing production and logistics structures reach their limits, isolated optimization measures are often no longer sufficient. This is where holistic factory planning demonstrates its true value: it enables processes, material flows, space utilization and technical infrastructure to be redesigned from the ground up, independent of legacy constraints with operational goals.
In the featured project example, three existing production sites of a plastics manufacturer were consolidated into a newly built greenfield factory in Morocco. The objective went beyond mere spatial consolidation – the aim was to create of an integrated, scalable and future-proof production structure that meets today´s operational demands while providing the capacity for sustained growth.
When Factory Planning Becomes Essential for Established Sites
Many manufacturing companies operate facilities that have developed organically over the years. Without systematic factory planning, this often results in:
- Redundant areas, functions and storage spaces
- Long, inefficient material and information flows
- High coordination effort across locations
- Limited potential for expansion and automation
A greenfield approach offers the opportunity to eliminate these structural weaknesses and build a powerful, integrated overall system.
Challenges in Site Consolidation
Merging several plants is a complex transformation project. In the Morocco project, the main challenges included:
Harmonizing Heterogeneous Processes
Different workflows, standards and organizational models had to be systematically aligned and unified
Transparency of Material and Goods Flows
Incomplete or inconsistent data initially complicated reliable material flow analysis and capacity planning
Space and Capacity Dimensioning
Balancing current utilization levels with future growth potential was critical to ensuring the economic viability of the new site
Ensuring Operational Stability During the Transition
Ongoing operations at the existing plants had to remain fully stable throughout the planning and implementation phases
Standardizing Machinery, Storage and IT Infrastructure
Different equipment setups significantly increased complexity, investment requirements, and training effort
Greenfield Planning as the Core of Factory Design
Greenfield planning integrates site selection, processes, space, infrastructure and data into a resource-efficient overall solution:
Cross-Site Material-Flow Analysis
All existing material, goods, and information flows were systematically documented and analyzed. This formed the basis for future production and logistics structures designed to minimize transport distances, shorten throughput times, and establish clear interfaces between functions.
Visualization and Reorganization of Space Utilization
A systematic visualization of production, storage, and traffic areas provided full transparency regarding actual space requirements. The resulting layout enabled compact, well-defined production zones while reducing secondary and traffic areas.
Standardization and Grouping
Machines, equipment, and utilities were harmonized to reduce complexity and variant diversity. Modular production areas were created that can be operated efficiently and expanded flexibly as demand evolves.
Storage and Intralogistics Concept
Warehouse functions were centralized and professionally structured, providing the foundation for transparent inventory management and a stable, reliable material supply.
Technical Infrastructure Planning
The technical infrastructure was designed from the outset with scalability and future-proofing in mind. Energy supply, media routing, IT systems, and automation structures were planned to accommodate future requirements without the need for major modifications.
Results and Measurable Impact
Through this methodological approach and holistic factory planning strategy, a solid foundation for structural realignment was successfully established:
- 25% reduction in total space requirements
- Efficient intralogistics with clearly defined material-flow structures
- Flexible layout enabling multi-machine operation and future automation
- Reduced process and organizational complexity
- High transparency and controllability across production and logistics
These results clearly demonstrate that systematic factory planning has a direct and measurable impact on operational efficiency and side-wide control.
Conclusion
Greenfield planning for the consolidation of multiple production sites enables the development of powerful, scalable manufacturing structures build for the long term.
The Morocco project shows how a methodological planning approach can transform heterogeneous sites into an integrated, future-ready production organization.
With clearly defined process and infrastructure planning, measurable efficiency gains and transparency are achieved, creating the foundation for future automation and sustainable growth.