SMART FACTORY
Innovative Industrialization.
Whether you're dealing with demographic shifts, a skilled labor shortage, or the demands of digital transformation, today’s production environment is more complex than ever. Add in other forces like de-globalization, rising cost pressures, and sustainability goals. Business challenges keep stacking up. The answer? A cost-efficient smart factory designed to meet the full potential of Industry 5.0, backed by the right partner.
At EDAG, we bring decades of product expertise and cross-industry production experience into the digital era to power your smart factory. The Industrial Metaverse is where all digital twins come together, uniting smart product with smart factory. From detailed ergonomics and throughput simulations to conveyor layout development and logistics engineering, we offer proven methods to improve safety, performance, and cost efficiency. Whether optimizing existing systems or designing facilities, we deliver tailored solutions backed by data, practical experience, and a deep understanding of manufacturing operations.
Our services in the U.S. cover key areas such as:
- Simulation & Process Optimization – We offer advanced digital simulations focused on ergonomics, access, assembly, and throughput to validate process flows and minimize risk before implementation
- Factory & Logistics Planning – From facility layout to material flow, we engineer the movement of goods within the four walls of your factory to ensure efficiency, scalability, and reduced waste
- Conveyor & Automation Engineering – We design and validate material handling systems, including AGVs, skillet lines, inverted conveyors, and overhead power-and-free (OHPF) systems tailored to your production needs
- Digital Twin & Virtual Commissioning – We leverage digital twins to virtually commission equipment, processes, and plant systems—enabling faster ramp-ups, fewer change orders, and a smoother SOP
Construction & Project Management – Acting as your owner’s representative, we manage construction activities from pre-construction planning through execution—ensuring quality, safety, cost control, and minimal disruption to operations.
Topic overview
Optimal Process Reliability
Achieving Process Reliability in Production
Process reliability is key to efficient and high-quality production. As experienced specialists in process optimization and Design for Manufacturing (DFM), we support product enablement by assessing manufacturability and production costs at an early stage—ensuring smooth and cost-effective production processes.
Sustainable Factory Infrastructure
In a lean, smart factory environment, sustainable building planning is essential. We integrate sustainable building technologies with comprehensive technical building equipment planning. Our support spans all work phases in accordance with the HOAI fee structure for architects and engineers. Throughout, we prioritize your specific requirements, including spatial design and energy efficiency.
- Our focus areas
- Optimize – products and processes across all development phases
- Ensure – manufacturability through digital product validation
- Evaluate – the maturity of technologies and components
- Analyze – ergonomics in manual production processes
- Guarantee – stable, efficient production operations
- Review – investments and component costs to secure the profitability of your smart factory
- Your benefits
- Accelerate – decision-making through a structured approach
- Create – economic added value for the overall project
- Optimize – operating costs (OpEx)
- Ensure – product and production quality
- Document – goals and results of product influence, backed by key performance indicators
Holistic Decision Support
Digital twins play a critical role in both production and production design. When paired with a unified IT infrastructure across the smart factory, they unlock major time savings by allowing development processes to run in parallel.
- Our focus areas
- Consultancy, concept development, and system validation – for effective implementation of digital twins
- Inspection of product, production, and building interfaces – ensuring seamless data consistency across all areas
- Virtual commissioning of smart factory systems – to enable faster, more efficient production ramp-up
- Early-phase digital factory visualization – supporting smarter planning and better decision-making
- Development of an integrated, centralized data platform – to enable real-time collaboration and control
- Profitability analysis with investment and component cost evaluations – ensuring financially sound decision-making
- Your benefits
- Innovative business models and increased efficiency – unlock business potential and streamline processes with the power of digital twins
- Smarter decision-making through visualization – enhance understanding and tackle complex challenges in smart factory environments
Sustainable Factory Infrastructure
In a lean smart factory, sustainable facility planning is a key success factor. We integrate eco-friendly building technologies with comprehensive technical building systems design, supporting you through all project phases in line with the HOAI framework for architects and engineers. Throughout the process, we stay focused on your specific requirements—considering spatial needs, energy efficiency, and overall building performance.
- Our focus areas
- Coordination of requirements – between production and infrastructure to ensure seamless integration
- Basic evaluation and general planning – involving specialized planners for optimal outcomes
- Project management oversight – handling all aspects from start to finish
- Digital safeguarding of factory processes and BIM – ensuring robust and efficient digital integration
- Monitoring the Total Cost of Ownership (TCO) – for long-term financial efficiency
- Implementation of cost reduction, efficiency improvements, and optimization projects – driving operational excellence
- Location analysis, selection, and planning – optimizing site choice for production needs
- Planning and executing decarbonization projects – supporting sustainability goals through effective solutions
- Your benefits
- Fewer interfaces – thanks to result-oriented general planning from a single source
- Cost reduction and efficiency improvement – driving bottom-line benefits through optimized processes
- Project security – ensured by digital protection from the inside out
- Tested and verified supply media – guaranteeing reliable media supply systems
- Customized responsibility for implementation – EDAG takes on tailored project management and execution
Supply Chain Excellence
Leverage supply chain excellence to build a more resilient network and optimize your logistics, suppliers, and distribution channels with the expertise of our specialists. By seamlessly integrating material and information flows, we help elevate your value chain to the next level.
- Our focus areas
- Holistic analysis, planning, and implementation – managing projects from tendering through to realization
- Optimization and digitization of your supply chain – enhancing intralogistics and supply processes for greater efficiency
- Robust networks – ensuring security of supply through resilient systems
- Increased efficiency – achieved through targeted process optimization
- Automation in transport logistics – streamlining logistics for better performance
- Process assurance – guaranteeing reliable and consistent operations
- Optimization of transport planning – improving supplier and container management for smoother operations
- Your benefits
- Boosting the efficiency of your supply chain – driving operational excellence and faster delivery
- Improved security of supply – ensuring consistent and reliable sourcing
- Reduced process costs and shorter response times – enhancing cost-efficiency and agility
- Adaptability of your smart factory – preparing for future challenges and growth opportunities
- Securing supplier quality – maintaining high standards across your supply network
- Promoting sustainability – integrating green practices for a more eco-friendly operation
Maximum Productivity
Cost pressures are rising, and the demands for efficient production continue to grow. To stay competitive, it’s crucial to regularly evaluate and optimize your smart factory processes while setting new benchmarks. As experienced professionals, we’re here to help you strategically boost your productivity.
- Our focus areas
- Safety Related Validation
- Gathering relevant parameters – through thorough system analysis for better decision-making
- Transparent presentation of costs and benefits – via detailed concept development
- Function-oriented, mechatronic development – integrating engineering solutions with precision and efficiency
- Quality planning – ensuring high standards across all stages of production
- Virtual safeguarding – protecting processes through digital simulations and testing
- Commissioning of smart factories – after comprehensive validation of all processes for smooth implementation
- Delivery of turnkey production solutions – providing fully integrated, ready-to-use production systems
- Your benefits
- Cash-flow-optimized investment plan – ensuring financial efficiency and flexibility
- Overall Equipment Effectiveness (OEE) – maximizing productivity and equipment performance
- Supplier-independent system component selection – customized to meet your specific requirements
- IT/OT architectures – enabling future-proof networking across all smart factory areas
- Production solution including CE conformity – ensuring compliance with European safety and quality standards
Mastering Complexity
We are digitization experts in process and production development. By combining deep domain knowledge with IT expertise, we enable future-proof system architectures, secure development and production environments, and process-reliable operations. This ensures complete complexity management across all areas of a modern smart factory.
- Our focus areas
- Automated, integrated engineering process – featuring material flow simulation, digital twin technology, and virtual commissioning
- Intelligent automation and flexible robotics – optimizing processes in production plants for greater efficiency
- Cyber-physical systems, MOM (MES), SCADA, and energy monitoring solutions – enabling seamless integration of operations and energy management
- Big data solutions – driving production optimization, quality management, predictive maintenance, and real-time information management
- Your benefits
- Reliable start of production – ensuring high productivity from day one
- Improved flexibility and efficiency – adapting quickly to changing demands and streamlining operations
- Transparent processes and rapid response times – fostering clear communication and quick decision-making
- Enhanced monitoring and control – gaining real-time insights into processes for better oversight
- Optimized planning and resource use – maximizing efficiency by effectively managing resources
Effective People in Production
By implementing effective solutions for digital collaboration, we connect employees and empower teams to work alongside and interact with intelligent systems within production.
- Our focus areas
- Collaboration solutions for projects – fostering seamless communication between clients, employees, service providers, and partners
- Digital platforms for networked factories – connecting all areas of the factory for better integration and efficiency
- Guided workflows and process documentation – supporting operations and quality management through clear, structured processes
- Training software for smart factories – enabling teams to upskill and stay ahead in a tech-driven environment
- Processes for optimization and secure decision-making – empowering management with data-driven insights for smarter choices
- Your benefits
- Increased efficiency of qualification measures – optimizing time, costs, and quality for faster results
- Reduction of the ecological footprint – minimizing environmental impact through sustainable practices
- Independent, proactive knowledge acquisition – empowering teams to learn without trainer dependency
- Training flexibility – allowing training to be carried out anytime and anywhere
- Improved learning success and reduced qualification times – accelerating “time to market” through better training outcomes
- Process reliability and efficiency – ensured by central documentation of product audit results
- Data-driven analysis and follow-up – leveraging data for predictive maintenance and other optimization processes
- Reduction of non-value-adding activities – streamlining operations through digitization
Let's talk about your use case now!
