Plant level

Dürr Consulting has extensive expertise in the development of manufacturing concepts for greenfield and brownfield projects. We also specialize in finding the ideal design for production and auxiliary areas and for the interfaces, with regard to the object flow, supply chain, quality, organization and communication.

In the creation of a new factory concept (greenfield), we leverage our expertise when planning and designing the production facilities from the ground up. We consider all relevant factors, such as the production flow, material flow and logistical requirements and the integration of state-of-the-art technologies.

For existing plants (brownfield projects), we carefully analyze the existing structures and processes. Based on this analysis, we develop optimized manufacturing concepts designed to increase efficiency, eliminate bottlenecks and maximize production capacity. Dürr Consulting places particular emphasis on the design of interfaces between the individual areas to ensure a smooth flow of information and materials. 

Regardless of whether it is a new or existing plant, we always use virtual technologies for factory planning, such as 3D solutions, to achieve even better results.

We support you in developing a site analysis for both greenfield and brownfield projects. In doing so, we consider all aspects of the production network as well as individual manufacturing sites. Our consulting approach, which we have refined over the course of numerous customer projects, considers, among other things, logistical aspects, political framework conditions, e.g., the funding landscape, infrastructure and site quality, but also demographic criteria and technical aspects. In feasibility studies for brownfield projects in particular, we consider and evaluate impacts on existing plants to assess the feasibility of technology integration, relocation, expansion or decommissioning. In greenfield projects, we leverage our tried and tested approach and our network of construction and real estate companies, as well as our contacts with government organizations.

Our technological know-how and understanding of processes, as well as our knowledge of critical interfaces, also helps us to conduct comprehensive assessments in brownfield projects and to create optimal solutions for our clients.

Taking into consideration the product, process, logistics, equipment and employees, we provide you with comprehensive process analyses as well as targets for your key performance indicators (KPIs) with a focus on production. In addition, we identify opportunities for process optimization to create optimization roadmaps. This is how we increase your performance and efficiency.

Case Study: Smart concept for flexible hydraulic motor assembly

We use our know-how in the field of process analysis and our holistic understanding of production to create optimal concepts, taking into account the product, process, IT, logistics, equipment and employees. Our established assessment approach helps to identify the challenges in your factory. In addition, we create KPI targets for you and identify opportunities in the existing process derived from the future production system requirements. To maximize the efficiency and performance of our customers, we support improvement by identifying concrete measures and roadmaps. To complete our portfolio of services, we accompany you through the change process and track its success.

Dürr Consulting helps your organization improve flexibility and versatility. We determine the drivers of your flexibility requirements and assess your existing technology and structure. At the same time, we identify opportunities for process optimization and adaptability. This enables us to identify your organization's flexibility requirements and implement targeted measures. With Dürr Consulting at your side, you can optimize your technology and way of working to respond effectively to changes and new requirements.

Learn how a flexibility assessment can help you reduce long-term adaptation expenses in greenfield projects and quickly adapt to changing economic conditions in brownfield projects.

A core competence of Dürr Consulting is our ability to assess and optimize production processes and equipment. It allows us to analyze their effectiveness and uncover opportunities for improvement. We also focus on the ergonomic and efficient design of workplaces and workstations to optimize work processes and increase productivity.