Fixed-price package · Shopfloor Analysis Intralogistics
Your lines are running. The material comes late anyway.
Two days at your plant, where we don’t look at the machines but at the routes between them: material flow, transport, buffers, floor space. Then the crucial part: from that input we build a digital twin of your material flow and quantify where your production is waiting for supplies – and what that costs.
Enquire about the Shopfloor Analysis →Fixed price €3,400 · two days on site · digital twin in visTABLE · final presentation
The problem
The bottleneck is rarely at the machine
A line can run as well as it likes – if the forklift doesn’t turn up, empties block the aisle, or pallets get moved three times before they reach the end of the conveyor, you lose performance at a point that never shows up in any machine statistics.
Routes that grew over timeThe layout has evolved over years, line by line. No one has ever looked at the material’s entire route from the loading bay to dispatch in one go.
Buffers as a symptomPallets are „temporarily stored“ everywhere. Every one of these buffers conceals a problem in the flow – and costs floor space you’re missing elsewhere.
Forklift traffic with no rhythmRuns happen on a shout. No one knows how many trips a day would actually be needed, or how many actually happen.
The line waitsPackaging material, labels, empties: if one of these supply chains snags, even the best line stands still – and the report later calls it a „technical fault“.
What happens when the layout just keeps growing
Every buffer conceals a problemPallets sit „temporarily stored“, floor space gets tight – and no one knows any more which buffer is a safeguard and which is a symptom.
The line waits, the statistics stay silentMissing packaging material, blocked aisles, empties in the way: the report later says „technical fault“.
Extended instead of tidied upA new building, new conveyor technology, a new warehouse – for routes that wouldn’t even exist with a different flow.
Before you buy or rent floor space, it’s worth looking at the routes you already have.
Enquire about the Shopfloor Analysis →Which package fits
Three formats, three different questions
So you don’t have to decide by price, but by need:
Tender Package
€480
The question: How do I describe a new machine so that I get comparable quotes?
Focus on: a machine that doesn’t exist yet
Fully online
Efficiency Day
€1,900
The question: Why does this one line stay below its target output?
Focus on: one line, during ongoing operation
One day on site
Shopfloor Analysis
€3,400
The question: Where am I losing time, floor space and distance between the lines?
Focus on: the material flow across the whole area
Two days on site
In short: the Efficiency Day looks at what happens in the line. The Shopfloor Analysis looks at what happens between the lines. If you’re not sure which format answers your question, we’ll call you and clarify it in a quarter of an hour – even if it turns out to be the cheaper one.
The turning point
This is what it looks like when the material flow becomes visible
What the final presentation puts on the table:
Before
With the package
Gut feeling about routes
A route diagram in your layout – every transport relationship in kilometres and hours per year.
Buffers everywhere
A clear distinction: which buffer is a safeguard and which is a hidden problem.
Layout ideas with no evidence
Variants calculated in the digital twin before anyone moves a single pallet.
Extending as a reflex
Measures ranked by Pareto – with expected savings, effort and a layout sketch for discussion in-house.
The scope of delivery
What you get
01
Two days on siteWe walk the material’s route – from goods-in through storage, staging and line supply to palletising, empties and dispatch. During ongoing operation, across more than one shift, so the handovers become visible too.02
Digital twin in visTABLEFrom your layout, positions and volume data, we model your material flow in visTABLE. That quantifies the routes – in kilometres and hours per year – and lets us calculate variants before anyone moves a pallet.03
Route diagram and assessmentThe routes actually driven and walked, drawn into your layout – that’s the moment the room goes quiet. Plus the assessment: which transports are necessary, which only exist because something else doesn’t fit; which buffer is a safeguard, which is a hidden problem.04
Measures ranked by Pareto – and a final presentationThe 20 percent of routes that cause 80 percent of the kilometres, first. Every measure with expected savings, effort and a layout sketch. Presented in a final presentation with a discussion round – objections welcome, they make the measures better.Closing round on the second dayThe most important observations, open and direct, before we leave.
The analysis is what mattersModelling, quantifying, calculating variants – that takes time after the two days. We fix the date for the final presentation in advance.
A fixed priceNo daily-rate discussion, no additional billing.
You keep everythingThe analysis, route diagram, presentation and sketches belong to you.
Enquire about the Shopfloor Analysis →Fixed price €3,400 · response within one working day
This is what the result looks like
An example from an analysis
Routes, volumes and times per transport relationship – from the digital twin, not from gut feeling. That means every measure can be evidenced in kilometres and hours per year.
The scope
What we look at
Goods-in and warehouseReceiving, put-away, inventory management, access times, routes to the point of use.
Line supplyPackaging material, labels, cartons, films: who brings what, when, in what quantity – and what happens when it’s missing.
Means of transportForklifts, tugs, tow trains, conveyor technology. Number of trips, empty runs, waiting times, crossing traffic in the aisles.
Buffers and floor spaceWhere material sits between steps, for how long, and how much floor space that ties up.
Palletising and dispatchFrom the end of the conveyor to the loading bay: transfer operations, load securing, staging.
Empties and residual materialsThe return route that’s almost always forgotten – and often causes the most disruption in the aisles.
The process
Who does what
You
- Provide us with a current floor layout – as a drawing or PDF. No layout, no route diagram; this is the one hard requirement
- Make sure production runs normally during these two days
- Provide a contact person from logistics or production
- Give us access to existing data: volumes, delivery frequencies, stock levels, transport orders
- Clarify photo permission in advance and send us your non-disclosure agreement, if you use one
Together
- We define the scope at the start – which buildings, which lines, which boundaries
- We talk to forklift drivers, shift leaders and logistics
- Closing round on the second day with the first findings – the final presentation follows after the analysis
POWERJO
- Records routes, times and volumes during ongoing operation
- Models your material flow as a digital twin in visTABLE and draws the route diagram into your layout
- Separates necessary from avoidable transports in the assessment – only this distinction turns an observation into a measure
- Signs your non-disclosure agreement in advance on request
- Presents the analysis, route diagram and measures in a final presentation – with a discussion round
Enquire about two working days →The one hard requirement: a current floor layout
Honestly
When it’s worth it – and when it isn’t
Good fit
- Your plant has grown and the layout evolved rather than being planned
- You have too little floor space and are considering extending or renting more
- Your lines regularly stand still because material is missing – even though there’s enough on site
- You want to know, before investing in conveyor or storage technology, whether there’s another way
- You’ve become blind to your own operation. Anyone who walks through this building every day stops seeing the detours – that’s not a weakness, it’s normal
Not a good fit
- It’s about the performance of a single line – then the Efficiency Day is the cheaper, better-suited format
- You’re expecting a finished warehouse plan or a detailed simulation of individual systems. That’s a separate project, and we’re happy to quote for it
- You’re looking for confirmation of a decision you’ve already made
- No production happens during the two days
Who’s coming
Joachim Quantz
I’ve overseen investment projects worth up to double-digit millions – for medium-sized businesses as well as international groups. That included new-build plants, where material flow had to be considered from the first line in the layout, as well as existing buildings, where every square metre ended up used differently from how it was originally planned.
Both help: I know what a flow looks like when it’s planned from the outset – and I know what constraints cause it to look different in reality.
Depending on the question, I bring in a colleague from the POWERJO network, for example from intralogistics or conveyor technology.
The price
One fixed price for both days
€3,400
For two days on site including travel there and back, the digital twin in visTABLE, route diagram, written analysis and final presentation. The fixed price applies within a 300-kilometre radius of Monheim am Rhein; beyond that, hotel stays are added, plus 19% German VAT.
Request a date →Enquiry
Tell us briefly where the material is getting stuck
You’ll get a response within one working day. If the Efficiency Day is the better format for your question, we’ll tell you that – even though it costs less.
Frequently asked questions
- What’s the difference to the Efficiency Day?
- The Efficiency Day looks at what happens within one line – cycle times, downtime, changeovers. The Shopfloor Analysis looks at what happens between the lines – material, routes, buffers, floor space. If your line runs fine technically but is waiting for supplies, the Shopfloor Analysis is the right format.
- Do we really need a layout?
- Yes. Without a floor layout, no route diagram can be drawn, and that’s the core of the analysis. A simple drawing or a PDF is entirely sufficient; it doesn’t need to be a current CAD model.
- What is the digital twin – do we need software for it?
- No. We model your material flow in visTABLE, a factory planning software: layout, sources and sinks, volumes and means of transport. That gives us the routes in kilometres and hours per year, and lets us calculate variants. You get the results as an analysis and presentation – the software stays with us.
- Do we need a non-disclosure agreement?
- If you use one: sure, send it to us before the appointment and we’ll sign it. If you don’t have one, we’ll provide one. With an analysis this thorough, we see volumes, stock levels and processes – that belongs in writing.
- Do the two days have to be consecutive?
- Not necessarily. Sometimes it makes more sense to put the second day on a different shift or a different weekday, because the workload is different then. We agree on that together in advance.
- Can you also implement the measures?
- Yes, as a separate matter. POWERJO provides on-demand project managers, process engineers and design engineers. Whether you want that is your decision after the analysis.
Fixed price €3,400Enquire now →