Individual process solution for solar inverters

KACO new energy is one of the world’s largest manufacturers of photovoltaic inverters and monitoring devices. The company runs offices in all major markets around the globe. Approximately 800 persons are employed in Germany and in the subsidiaries in the United States, Canada, Spain, France, Italy, Greece, Israel, China South Korea and other countries.

Project challenges

KACO new energy quickly reached the limits of the existing production capacity. To meet the market’s continuously rising demand, KACO’s management decided to build an additional assembly plant for photovoltaic inverters.

io-consultants was responsible for the development of an assembly and logistics concept adjustable to all options which was to be integrated in the existing building concept. The crucial requirement during assignment was the planning of a modern, highly flexible, scalable and CO2-neutral facility with pioneering production processes and quality control devices.

Assembly and logistics concept for factory expansion

Logistics planning, Factory planning

Neckarsulm, Germany

Customer value

During concept design phase, the production areas were verified and technical systems selected. Layout options were evaluated via a value stream analysis. The production and logistic equipment was to be integrated into the approved construction plan.

The main focus of the project was on production with a fully automated inspection system where converters undergo an endurance test, automated pallet storage with 1,100 locations and a small parts warehouse with 16,000 locations.

Please contact us 

Julius Weis Partner Phone: +49 (0) 62 21 / 379-190