Opening a new site by building on what already works
A growing SME is opening a second site. The project is moving forward, but the new site starts almost from scratch: new tools, redesigned processes, and the first site’s history (volumes, lead times, incidents, workload per role) remains scattered across several tools or is not annotated well enough to be reused. The plan is to hire five people in the same roles as at the first site, when better use of the history could have optimized hiring, roles and equipment.
With every new site, as with every “optimized” overhaul of a production site with new tools, historical business data is poorly reused. Sizing decisions (headcount, roles, equipment) rest on assumptions, when the history could show that it is better to hire three people rather than five, in different roles, and to invest in an innovative piece of equipment that lifts the site’s performance.
- 01 Recover and harmonize the historical data of existing sites: volumes, lead times, workload per role, incidents.
- 02 Model processes and capacities in a digital twin: flows, roles, equipment, costs.
- 03 AI agents that simulate opening scenarios (volumes, organization, hiring, equipment) and compare their effects.
- 04 Start the new site on digitized processes that carry over what existing sites have learned.
- Sizing based on history, not assumptions
- The right roles, in the right numbers, with the right equipment
- A new site that starts with what the others learned
- Risks anticipated before investing