Designing a new plant, from a bare site to the file submitted to government.
A European maker of precision energetic components for defence wanted to create capacity for several hundred million parts a year on a new site. CORE carried the study end to end: site and buildings, process, lines, make or buy, regulations, organisation, funding and the submission file for the authorities.
What CORE did
Site and buildings
Feasibility study, site master plan, building envelope, layouts and flows for two products, building options compared.
Capacity and process
Capacity calculator, OEE scenarios, process split into zones, batch definition, FMECA and control plan.
Line design
Five identical lines, every station described, quoted with suppliers and costed bottom-up, with contingency.
Make or buy
Make-or-buy analysis of key components, part standardisation, supply chain and raw-material resilience, supplier due diligence.
Regulations
Major-accident hazard screening (Seveso type), explosive atmospheres and ATEX zoning, storage of dangerous goods.
Logistics
Four logistics scenarios between buildings and sites, work-in-progress transit times, packaging and haulage benchmark.
Organisation and skills
Launch roles, labour and salary model, key skills, hiring and training plan with a university partner.
Funding
Financial model of the investment and preparation of a capital grant application.
Government submission
Submission packs for the sponsoring ministry: volume and product-mix plan, labour model, skills, supplier due diligence, preliminary process diagram and sensitivity analysis.
Information security
Cyber security policy and secure document-sharing procedures, fitted to the sector's requirements.
The result
The concept held up, and it came out smaller and cheaper than the first sketch. Three of the five critical findings open at the start were closed during the study. The client now has a defensible cost basis, a file ready for the authorities and a four-step roadmap: product engineering, a single-lane validation line, a layout study, firm quotes.
What it shows
The C.O.R.E. method works upstream of a project too. We clarify the facts and constraints, optimise the concept, strengthen the file, and the investment starts on solid ground.
The client's name, products and detailed data stay confidential. Figures are rounded.