Plant Planning

Planning Overview

Qicheng specializes in metal forming and focuses on smart factory planning and design. Led by a PhD with more than 30 years of plant-wide experience, our team combines architecture, lean production, logistics planning, process engineering, equipment and automation, digitalization and simulation. Using our proprietary 645 methodology, we provide one-stop solutions covering process optimization, workflow design, building parameters and workshop planning, warehousing and logistics, automation equipment selection, digital deployment and 3D simulation validation, helping manufacturers build industry-leading smart factories.

High efficiency

Low cost

Automation

Intelligence

Video: a smart factory planned and built with Qicheng

Planning Benefits

+30%

Overall efficiency

Systematic coordination of people, machines, materials and methods

-60%

Transport distance

Logistics routes minimized according to process flow

-35%

Work-in-process inventory

Smooth process handoffs reduce intermediate stacking

-30%

Labor input

Automation replaces manual loading, unloading and transfer

-10%

Overall energy consumption

Coordinated optimization of equipment selection and energy configuration

-3%

Building cost

Compact layout reduces unused floor area

Planning Outcomes

Higher operational efficiency and management level

Scientific calculation and rational layout

Advanced automation for efficient production

Integrated air, sea and land intelligent logistics

Real-time, efficient and transparent

Green, energy-saving and environmentally friendly

Architecture designed around the product process

Integrated lean production and layout

Visitor-friendly design

Smart Factory Planning Process

The 645 methodology: 6 stages, 45 steps

Stage 1 Planning Requirements and Research
  1. Executive interviews
  2. Future positioning of the new plant
  3. Production process research
  4. Future capacity planning
  5. Product PQPR analysis
  6. Logistics PFE planning
  7. Area requirements by zone
Stage 2 Campus and Building Planning
  1. Site information review
  2. Building footprint planning
  3. Floor count and clear-height planning
  4. Column grid and load-bearing planning
  5. Elevator and stair planning
  6. Site-wide logistics planning
  7. Logistics correlation analysis
Stage 3 Functional Zone Planning
  1. Logistics volume analysis
  2. Area planning by functional zone
  3. Staff and equipment resource calculation
  4. Logistics equipment selection
  5. Warehousing and logistics planning
  6. Automatic logistics planning by zone
  7. Visitor route planning
Stage 4 Overall Layout Planning
  1. Workshop product PQ analysis
  2. Product family grouping
  3. One-piece flow design
  4. Line-side warehouse and material supermarket planning
  5. Delivery model planning
  6. Workshop logistics route planning
  7. Tooling and fixture planning
  8. Production line and automation design
  9. Equipment layout planning
Stage 5 Supporting Function Planning
  1. Equipment power load
  2. Water, electricity and gas routes
  3. Employee rest areas
  4. Canteen and dormitory
  5. Offices and showroom
  6. Utility network and cable tray planning
  7. Digitalization planning
  8. Simulation analysis and improvement
Stage 6 Implementation Coaching
  1. Relocation budget and implementation plan
  2. Utility installation follow-up
  3. Equipment relocation follow-up
  4. Three-zone site planning
  5. Plant-wide visual management plan
  6. Employee rest area development
  7. Benchmark workshop operation

Case Studies

Automotive parts smart factory planned by Qicheng

Automotive Industry

Project background

This new automotive parts plant covers 426 mu, with workshops for cutting and blanking, stamping, welding, roll forming, tooling, machining, scrap handling and warehousing. The project covered layout and logistics planning, automation and line planning, support facility design, digitalization planning, end-effector standards, die standards and stamping line operating standards.

Project results

  1. Production efficiency increased by 30%
  2. Work-in-process inventory reduced by 40%
  3. Transport distance reduced by 50%
  4. Space utilization increased by 30%
  5. Labor reduced by 30%
  6. 5S and visual management on the shop floor significantly improved
Home appliance factory workshop layout planned by Qicheng

Home Appliance Industry

Project background

This new kitchen appliance plant covers 226 mu, with workshops for cutting and blanking, stamping, welding, assembly and warehousing. The project covered layout and logistics planning, automation and line planning, support facility design and stamping process optimization.

Project results

  1. Production efficiency increased by 25%
  2. Work-in-process inventory reduced by 45%
  3. Transport distance reduced by 50%
  4. Space utilization increased by 40%
  5. Labor reduced by 20%
  6. 5S and visual management on the shop floor significantly improved