In brief
Factory planning costs mainly depend on plant size, planning depth, data quality, the number of variants and implementation support. A serious estimate breaks the project down into work packages, roles and decision loops; a generic percentage of investment cannot replace this effort estimate.
Five central cost drivers
- System size: Number of areas, products, processes and interfaces.
- Planning depth: From feasibility through an implementation-oriented detailed layout.
- Data quality: Cleaning and completing incomplete data requires time.
- Number of variants: More scenarios improve insight but increase modelling and evaluation effort.
- Implementation: Tendering, award, relocation and ramp-up are separate service modules.
Typical cost blocks
| Module | Typical results |
|---|---|
| Analysis | Objectives, volume model, data model, current layout and constraints |
| Structural planning | Space requirements, functional diagram, ideal and feasible variants |
| Detailed planning | Detailed layout, workstations, technology, utilities and specifications |
| Implementation support | Tender, award, construction phases, relocation and ramp-up |
Three transparent calculation examples
The following figures are deliberately simplified calculation examples, not price quotations or reference projects. They illustrate how effort can be estimated.
- Compact feasibility study: 2 planners × 20 working days = 40 person-days.
- Structural and variant planning: 3 planners × 40 working days = 120 person-days.
- Planning with detail and implementation: 5 roles × an average of 60 working days = 300 person-days.
The commercial framework then results from person-days, agreed day rates, travel and incidental costs, and any software, scanning or specialist planning services. A robust estimate therefore requires at least a target definition, system boundary and agreed deliverables.
Why insufficient planning can become expensive
Omitted variants, unclear interfaces or unchecked volume assumptions shift decisions into implementation. Changes are more expensive there because procurement, construction, production and deadlines are already interdependent. Good planning does not eliminate every uncertainty, but it makes uncertainty visible and manageable.
Also read the five-phase process, the required data basis and our factory planning service.