to select the optimal scenario, plan batch sizes, verify machine utilization, and size WIP and packaging.
Automotive & Industrial Components
Confident start of production under tight space and capacity
Logio prepared and implemented an end‑to‑end internal logistics concept for a Megatech plant in Pilsen, integrating a new production project into existing operations.
Outcome
The solution covered material flow from receiving to dispatch and was validated with dynamic simulation, enabling a smooth ramp‑up despite space and capacity limits.
About Megatech
Megatech Industries is an international automotive supplier specializing in plastic interior and exterior components, headquartered in Vaduz, Liechtenstein, with operations including sites in Czechia. In 2025 the company was acquired by SAPA as part of SAPA’s global expansion.
~2,200 employees (global)
Presence in 9 countries
Czech sites include Plzeň and Jablone
Initial challenge
Integrate a new production project into an already running plant while solving capacity constraints and lack of space.
Project goal
Design and implement a comprehensive internal logistics concept, from goods receipt to dispatch, and prepare the plant for Start of Production.
Solution
Validating the concept with a digital twin
Logio designed the future internal logistics, aligned processes and systems, and used dynamic simulation to compare variants and de‑risk the SOP.
Solutions implemented
Dynamic Simulation
Production Ramp‑up Support
Process Mapping & Analysis
Information Systems Assessment
Impact
Confident start of production with the right capacity
Smooth SOP ramp‑up, no surprises
Dynamic simulation de‑risked implementation and supported stable mass production start.
Right‑sized WIP and packaging
Model defined stock and container needs ahead of go‑live.
Verified machine utilization
Scenarios tested and validated capacity before changes on the shop floor.
End‑to‑end process readiness
Logistics from receiving to dispatch aligned with updated IS and new layout.
Make your SOP predictable
If your plant is adding new programs into constrained operations, we can design, simulate and deliver an SOP‑ready internal logistics concept. Let’s talk about de‑risking your ramp‑up with evidence, not guesswork.
We tackled many supply chain challenges
Intralogistics optimization for Trane Technologies
Logio mapped intralogistics, built missing data inputs, and designed a warehouse and material‑flow reorganization at Trane Technologies—targeting up to 30% productivity improvement and lower logistics costs.
Up to 30% productivity (planned)
Spare parts optimization for Pars nova
Pars nova gained a clear view of its spare parts portfolio, identified dead stock and duplicates, and received a BI tool to sustain improvement.
45 % of spare parts evaluated as potential dead stock