Optimization of the production network

As one of the leading CNC machine tool manufacturers in the field of metal cutting, Gebr. Heller Maschinenfabrik GmbH employs 2,050 people worldwide. Five production sites in Europe, Asia, and North and South America ensure reliable delivery to customers around the globe.

A high‑performance production network is essential to secure delivery reliability, efficiency, and flexibility in a global competitive environment. Gebr. Heller Maschinenfabrik GmbH faces the challenge of adapting its production network to significantly changed market requirements and repositioning itself both strategically and operationally. The goal of the project was to create a sound basis for decision‑making for the future footprint – providing transparency on investments, savings, and the direct effects on the company’s profitability.

In the first project phase, each site’s performance profile and KPIs, production program, portfolio and make‑or‑buy decisions, as well as the underlying forecast assumptions, were systematically collected and harmonized. In the second phase, the results were consolidated into a cross‑site overall view, visualized, and aligned with stakeholders, including a neutral reference scenario as a comparative baseline. Building on this, several network scenarios (“footprints”) were evaluated, including the respective business cases (investments and savings), and prepared as a basis for decision‑making.

Within just seven weeks, an additional simulation model was developed, enabling transparent scenario analysis of various parameters within the global production network – for example, changing market assumptions or an adjusted production program. Close collaboration with the internal project team, along with the availability of data, access, and resources, allowed for high speed and robust results. The outcome is a prioritized action and implementation plan to realize the recommended target structure.