We use cookies, similar technologies and tracking services

This website uses cookies, similar technologies and tracking services (hereinafter referred to as “Cookies”). We need your consent for Cookies, which not only serve to technically display our website, but also to enable the best possible use of our website and to improve it based on your user behavior, or to present content and marketing aligned with your interests. For these purposes, we cooperate with third-party providers (e.g. Salesforce, LinkedIn, Google, Microsoft, Piwik PRO). Through these partners you can also receive advertisements on other websites.
If you consent, you also accept certain subsequent processing of your personal data (e.g. storage of your IP address in profiles) and that our partners may transfer your data to the United States and, if applicable, to further countries. Such transfer involves the risk that authorities may access the data and that your rights may not be enforceable. Please select which Cookies we may use under ”Settings”. More information, particularly about your rights, e.g. to withdraw consent, is available in our Privacy Policy .

Settings

Only technically necessary Cookies

Accept everything

Legal Notice

Below, you can activate/deactivate the individual technologies that are used on this website.

Accept All

Essential

These Cookies make a website usable by providing basic functions such as page navigation, language settings, Cookie preferences and access to protected areas of the website. Cookies in this category additionally ensure that the website complies with the applicable legal requirements and security standards. Owing to the essential nature of these Cookies, you cannot prevent their use on our website. Details about these Cookies are available under 'More information'.

Functionality and personalization

These Cookies collect information about your habits when using our web pages and help us to enhance your user experience by tailoring the functions and attractiveness of our web pages based on your previous visits, location and browser settings. They also enable access to integrated third-party tools on our website (e.g., Microsoft Azure for single sign-on authentication). This can involve transferring your data to the United States (for information on the risks involved read Clause 1.5 of our Privacy Policy). If you refuse these Cookies, you might not be able to access the full functionality of the website. Details about the tools we use are available under 'More information'.

Analysis

These Cookies are used to compile basic usage and user statistics based on how our web pages are used (e.g. via Google Tag Manager, Piwik PRO). If you accept these Cookies, you simultaneously consent to your data being processed and transmitted to the United States by services such as Salesforce Pardot (for information on the risks involved read Clause 1.5 of our Privacy Policy). Details about the tools we use are available under 'More information'.

Marketing and social media

These Cookies help third-party sources collect information about how you share content from our website on social media or provide analytical data about your user behavior when you move between social media platforms or between our social media campaigns and our web pages (e.g., LinkedIn Insights). Marketing Cookies from third-party sources also help us measure the effectiveness of our advertising on other websites (e.g. Google Ads, Microsoft Advertising). We use these Cookies to optimize how we deliver our content to you. The third-party sources and social media platforms we use can transfer your data to the United States (for information on the risks involved read Clause 1.5 of our Privacy Policy). If you accept these Cookies, you simultaneously consent to your data being transferred and processed as described above. Details about the tools we use and our social media presence are available under 'More information'.

Back
More information

Save Settings

Legal Notice

Automotive Brownfield Integration

Implement new vehicle architectures in existing plants on schedule, reliably, and scalably

Are you looking for excellent consultants and engineers who can modernize and optimize existing automotive plants, prepare them for new vehicle architectures, and understand what matters in a real production environment? 
Dürr Consulting is your expert partner for integrating new vehicle architectures into existing production facilities. We ensure that your production can operate in a future-proof way.

Integrating new vehicle architectures into existing automotive plants is complex: ongoing production, limited space, existing equipment, IT/OT landscapes, safety requirements, and strict SOP deadlines must be precisely coordinated. This is precisely where practical implementation experience counts.
At Dürr Consulting, we understand the complexity involved in integrating new vehicle architectures into existing automotive plants thanks to our extensive project experience. To meet these challenges, we offer tailored solutions that future-proof your production and ensure a smooth production launch.

Our goal is to efficiently and seamlessly implement the adaptation, modernization, and optimization of production processes in brownfield environments. Using proven methods, realistic planning scenarios, and a clear focus on production flexibility, resilience, and costs, Dürr Consulting supports OEMs and suppliers in implementing brownfield integrations with low risk, on schedule, and sustainably—today and for future model generations. 
We have many years of experience in consulting and implementing integration projects. From the initial idea to series production (SOP), we stand by your side and support you every step of the way.
We rely on proven concepts combined with innovative ideas to optimize your automotive production. This includes customized layout planning, state-of-the-art plant concepts, the development of integration strategies, and realistic schedules tailored to your specific requirements. In addition, we design optimizations that enable long-term production flexibility and facilitate future integrations and changeovers.

Our focus:

  • Integration of new technologies and production processes into existing plants
  • Customized process optimization, equipment and layout planning, and the development of specific integration strategies tailored to your requirements
  • Realistic timelines for the smooth implementation of your modernization projects
  • Future-proof solutions that enable flexibility and scalability for future changes

Our approach:

With comprehensive consulting and practical support, we guide OEMs and suppliers through an efficient and successful transformation of their automotive production—secure, predictable, and future-oriented. Leveraging the market leader’s wealth of experience, we support the introduction or conversion of vehicle architectures, manufacturing technologies, and production processes in existing plants—including modernization, optimization, retrofitting, retooling, and ramp-up management through to series production (SOP). 
The challenges in such brownfield environments are diverse: production downtime must be minimized, existing equipment adapted, processes optimized, and production flexibility ensured for future model changes.

Our services:

1) Strategy & Vision

  • Assessment of the initial situation (technology, space, material flow, IT/OT, equipment)
  • Definition of target architecture and integration principles (e.g., modularity, scalability)
  • Business case and risk/feasibility analysis

2) Layout planning, material flow & process optimization

  • Process mapping and identification of bottlenecks and potential solutions
  • Brownfield layout planning under constraints (space, utilities, escape routes, existing infrastructure)
  • Material flow & logistics concepts (supermarket, tugger train/AGV, JIS/JIT)
  • Integration of ergonomics, occupational safety, maintenance, and accessibility

3) Integration & conversion planning (during ongoing production)

  • Integration strategy (phasing, cutover, parallel operation, minimization of downtime)
  • Schedule and implementation planning with realistic timelines (milestones, gate logic)
  • Coordination of interfaces: plant engineering, buildings, utilities, IT/OT, quality, production

4) SOP Preparation & Ramp-up management

  • Start-up concepts, capacity and cycle time analyses
  • Maturity/readiness checks, acceptance and testing concepts
  • Support through SOP and stabilization of series production

5) Optimization & Future-Proofing

  • Flexibility concepts for variants, volumes, and future integrations
  • Layout/line optimization, bottleneck analysis, OEE improvements
  • Standardization and documentation (e.g., template set for future rollouts)

Questions for the Consulting Team:

How does Brownfield differ from Greenfield?
Brownfield works with existing buildings, equipment, and constraints. Greenfield starts “from scratch” and offers more planning freedom—but is often more capital-intensive.

What is automotive brownfield integration?
The integration of new vehicle architectures, processes, or technologies into an existing plant—including retrofitting, modernization, and optimization while production continues.

How do you minimize downtime in a brownfield project?
Through phased planning (phasing), cutover strategies, parallel operation, precise interface coordination, and realistic scheduling and resource planning.

Does Dürr Consulting provide support through to SOP?
Yes. We provide support from the initial idea through layout and integration strategy to ramp-up and SOP, as well as during the stabilization of series production.

What results can I expect?
Greater implementation reliability, transparent dependencies, reduced risks through to SOP, improved layout and material flow quality, and greater flexibility for future changes.

Typical brownfield challenges we solve:

Our approach:

Contact us!

Trust Dürr Consulting – shape the future of your automotive production with experts in automotive brownfield integration.

Dr. Susann Kärcher
Senior Manager
Automotive
Dürr Systems AG
Carl-Benz-Str. 34
74321 Bietigheim-Bissingen
Germany
 Business Card.vcf
Newsletter