Factory Capacity increase through Layout and Process Optimization
Driving sustainable capacity growth in complex manufacuring environments
MilliporeSigma, the Life Science business of Merck KGaA, Darmstadt, Germany, is a leading supplier to the global Life Science industry.
Facing rising capacity demands, MilliporeSigma’s manufacturing site in Bedford, Massachusetts partnered with Siemens Advanta to unlock additional production potential through data-driven layout and process optimization - without expanding the existing factory footprint.
- Rapid organizational growth combined with limited available factory space
- High-mix, low-volume production portfolio with complex material flows
- Strict regulatory and compliance requirements limiting structural changes
- Increasing pressure to improve capacity, availability, and throughput without site expansion
Siemens Advanta delivered a holistic, system-level approach to factory planning and optimization, applying a structured, data-driven methodology:
- Digital Factory Modeling: Creation of detailed 2D and 3D factory layouts to enable transparent analysis of current-state processes and flows.
- Layout Optimization: Redesign of value streams, process clustering, and interface improvements between major production stages.
- Process Optimization: Advanced planning and scheduling concepts to improve line balancing, availability, and cycle times
- Simulation-Based Validation: Evaluation of optimization scenarios using simulation models to validate performance improvements before implementation.
This integrated approach ensured measurable results while minimizing operational risk.
The implementation delivered significant and sustainable improvements across the production system at MilliporeSigma:
- >100% capacity increase potential identified within the existing brownfield site, without physical expansion
- ~40% improvement driven by layout and material flow optimization
- ~60% uplift achieved through process optimization, planning, and scheduling enhancements
- ~30% additional space identified to enable future expansion
- Over 25 improvement measures qualified and prioritized for implementation
The solution provides a scalable blueprint for future growth, enabling MilliporeSigma to meet long-term demand while maintaining regulatory compliance and operational excellence.
Our industry leader
Contact Us