Future ready production layoutfor a medical technology company

How vision, structure and Lean methodology helped design a factory that is modular, efficient and ready for growth.

When a company introduces a new product, more changes than just the material flow.
The entire factory changes.

That was exactly the situation at a medical technology company that launched a new modular product as an extension of its existing product family.

The challenge

The existing layout had grown over time. It was historical, constrained and not suited to the new product architecture.

Simply rearranging a few machines would only have led to short term fixes. What was needed was a genuinely future oriented factory planning approach.

The starting point: Creating a shared vision

Before working on drawings, material flows or takt times, we conducted a vision workshop.

Together, we answered key questions:

  • How do we want to produce in the future

  • What makes our production more efficient, flexible and stable

  • What role does modularity play in value creation

  • How must assembly, testing processes and logistics interact

  • What conditions does a factory need to remain suitable in ten years

The result was a clear plant vision that served as a guiding star and formed the foundation of the entire factory planning process.

From vision to reality: Layout and takt workshops

With this vision in place, we moved into structured, methodical work:

  • layout workshops to develop different variants

  • material flow analyses to minimize movement

  • takt workshops to define clear takt structures for the new modular product

  • interface analyses to optimally align logistics, assembly and quality

  • evaluation of layout variants based on Lean principles, ergonomics and future readiness

Step by step, a layout emerged that not only worked for the new product, but also provided a scalable production platform for future developments.

The result: A layout that enables growth

The final production layout delivered multiple competitive advantages:

  • clear and flowing value streams

  • modular assembly stations for rapid adaptation

  • reduced transport distances

  • stable takt structures

  • higher transparency on the shop floor

  • ergonomically optimized workstations

  • integrated quality assurance

  • future ready logistics concepts

Factory planning was not just a technical exercise. It was a strategic step toward long term viability.

Why this story matters

Because good factory planning is more than moving machines around.

It is the art of bringing vision, processes, people and product architecture together.

And because a strong layout does not only deliver results today.
It creates the foundation for a company to remain efficient, flexible and high performing tomorrow.

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