Building a new factory from the ground up requires extensive planning, efficient project management, and a deep understanding of production processes
In this case, our client needs to establish a completely new factory to manufacture a new product family they have no prior experience with.
They require a complete factory layout covering all production processes and material flows, as well as a business case with financial calculations, including investment and payback time.
Challenge
The client is operating under a very tight schedule, as they need to present a solution within three months of initiating the collaboration.
They want to locate production in Jutland and have high safety requirements that the facilities must meet. The production involves a wide range of technologies, from heavy steel industrial processes to machining, coating, chemical processes, ATEX zones, and quality control. Designing the most optimal factory, therefore, requires extensive knowledge of production processes and advanced technological solutions, as well as expertise across multiple specialist areas.
Additionally, the production must run with a takt time of 60 seconds and be adaptable to one, two, or three shifts depending on demand.
kaastrup|andersen’s consultants are tasked with developing a proposal for a greenfield factory, covering the entire process—from buildings, production equipment, organisation, budget, and business case to staff recruitment, logistics, and advanced technological solutions.
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"Building a factory from scratch requires deep insight into both production processes and project management. In this project, we focus on delivering a solution that meets the client’s high standards for technology and safety while optimising the production flow. Through close collaboration and thorough analyses, we deliver a scalable and future-proof factory design—within the tight deadline."
Solution
Our solution follows a structured process:
- Product analysis: We define and document the necessary product and production technologies and analyse uncertainties through extensive research.
- Process analysis: We collaborate with equipment and process suppliers to verify critical processes and ensure realistic and practical solutions.
- Mapping of production flow: We benchmark the client’s desired production flow against leading Danish manufacturing companies.
- Supply chain: We develop an efficient supply chain, covering material supply, inventory management, takt time, and calculations for required robotics and energy optimisation.
- Layout: We design production, warehouse, and administration buildings to support optimal flow. Outdoor areas are planned with accessibility, safety, and logistics in mind. Buildings, flow, inventory, and outdoor spaces are structured for future growth and scalability.
Based on these analyses, we prepare a comprehensive proposal for the client, including:
- A complete factory layout covering all production processes and material flows.
- A proposal for the factory’s location, including the cost of land and site development.
- A staffing plan covering all phases from start-up to full operation.
- A business case with a budget including both CAPEX and OPEX.
The solution requires deep expertise across multiple specialisations. Therefore, we assemble a team of eight colleagues with complementary skills at different levels to ensure optimal project execution.
Solution
Through close dialogue and frequent updates at steering committee meetings, we ensure that the client's requirements are continuously followed and aligned throughout the process.
We deliver a complete solution proposal, which includes:
- Detailed drawings and descriptions of all processes, flows, logistics, storage requirements, and staffing plans.
- Proposals for suppliers of equipment and buildings, as well as outdoor areas.
- A final staffing plan from start-up to full operation.
- Proposals for site selection and land acquisition, along with a project management plan leading to full production capacity.
- Business case and budget.
The proposal is delivered within the agreed timeframe, and the client was ready to present the project to their own customer.
Our client rated the project with a customer satisfaction score of 10/10.
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