Plant Optimization

In a competitive environment with increasing individualization of mass production, production line performance and efficiency are declining. This is due to changing personnel with a low level of training as well as frequent line changes. This leads to enormous efficiency losses, especially in aseptic lines. Declines in sales are offset by large investments in new plants, which would not be necessary for the planned production capacity.

The aim is to generate greater line efficiency with existing equipment. With increasing product individualization, this increases both sales and earnings and prepares the company for the competition in a resource-saving manner.

With a focus on productivity analysis and efficiency, our consultants take stock of the actual situation of the production line(s). We make assessments of plant performance and identify vulnerabilities for which we derive concrete optimization measures.

After joint evaluation of the optimization possibilities, we work with our clients to design efficient and cost-saving processes on and in the line so that productivity remains at a high level. The cost-benefit analysis of the optimization potential is followed by the implementation of improvement measures and line adjustments.

Our service portfolio includes the metrological processing of plant availability (OEE), the adaptation of existing lines for the realization of individualized mass production, as well as process reengineering to enable key figure-based plant control.

With the wide range of optimization strategies, ensign advisory can provide clients with effective results, including a 5% to 15% increase in capacity and a 10% to 15% increase in line performance, thanks to higher utilization and more efficient processes. The application of optimization solutions leads to lower product manufacturing costs and important savings in energy and material consumption.