… we understand the special needs of mentioned industries.
The successfull completion of various national and international projects is a trustful indicator for our expertise and experience in optimal coordination and processing of projects due to individual customer demands. It is our practical and specific approach that guarantees successful projects and satisfied customers.
GREENFIELD FACTORY PLANNING
An automotive supplier’s expandable injection molding facility was re-planned from scratch (Greenfield). The initial layout can be extended to maximum configuration according to future development.
The project course was structured into rough and detailed planning. Rough planning includes the calculation of area requirement for each functional area and their ideal disposition. Machine layout, storage system concepts, an optimum flow of materials and 3D-visualization were part of the detailed planning. The orientation of the plant on property was considered for both – connection to optimal public transportation routes and least possible leveling of property (earthworks).
PROCESS DESIGN AND PRODUCTION LOGISTICS
For one of our customers we designed the production process of car center consoles which were injection molded and assembled in a factory in Mexico. The challenge was to ensure the ability to supply “just-in-sequence” to the OEM production line and to determine the batch production at optimal costs of the required 11 components in 4 colors on 4 different injection molding machines - at the same time. Our scope of services involved batch size optimization and the sizing of the supermarket considering the variable set-up time.
CLEAN ROOM CONCEPT
The integration of a new production line to manufacture and assembly multi-chamber injection molded objects for the medical sector required clean room cascades with classification grades D, C and A. MPC therefore developed various scenarios of how a clean room layout could be integrated step-by-step into the ongoing operation. The target concept had to fulfil certain requirements regarding a flexible and easily accessible cascade concept which is arranged for optimum material flow without disregard to operating costs and productivity during the conversion phase.
RELOCATION AND INTEGRATION
The initial scope was to evaluate the future development of three plant sites. So before action was taken, alternatives were considered and the integration of two factories in location 1 was determined. The relocation was planned and implemented afterwards. As a consequence the reliability was increased and the relocation costs were decreased. In total, 140 plants and 420 peripheral elements were successfully relocated.
CONCEPT AND TECHNICAL INSTALLTIONS FOR AN INJECTION MOLDING FACTORY IN CHINA
To plan a factory from scratch (Greenfield) for a german manufacturer of domestic appliances, MPC designed a sustainable injection molding factory layout (to be built in China) which follows the principles of ideal material flow. We performed the engineering and the tendering process for the technical building equipment and production media supply for the initial and maximum configuration of the factory. MPC supported the customer locally with project management, technical monitoring and coordination of suppliers. MPC also assumed responsibility for scheduling and budget of technical trades. One of our main targets was to guarantee high technical and qualitative standards with local suppliers.
In the present case the task was to design an ideal configuration of machine layout and transport system for a new factory structure. The operating costs could be reduced substantially due to the implementation of a tugger train and a milkrun concept. Furthermore, the work contents of production and transportation were decoupled and the packaging and transporting units were standardized.