Automotive & Industrial

Unlocking hidden capacity through production and logistics optimization

Logio partnered with SIGMA Group to analyze and redesign the production and logistics layout at their manufacturing facility in Lutín, delivering a data‑driven concept for more efficient use of space and smoother material flows.

Outcome

The project identified significant untapped potential in how production and warehouse areas were organized. The optimized concept frees up over 1,300 m² of floor space, shortens material handling routes by 10–20%, and provides a clear investment roadmap with a 4–6 year payback period.

Total released space

+0 m²

Internal logistics routes

-0%

Return on investment

in 0 years

About SIGMA

SIGMA Group is one of the traditional European manufacturers of pumping equipment with a long history dating back to 1868 and a strong position in the field of industrial applications. The company focuses on the development and production of water pumps for industry, energy and water management.

Founded in 1868

501–1,000 employees

12+ subsidiary companies

Initial challenge

SIGMA Group needed to make better use of its existing production and warehouse space without major construction investments. Internal material flows had become complex, handling routes were longer than necessary, and the current layout limited further growth of manufacturing capacity.

Project goal

Deliver a comprehensive analysis of the current production and logistics setup, including layout and material flows, and propose an optimized concept with multiple implementation variants, each supported by an investment case and economic evaluation.

Solution

From floor‑plan analysis to an actionable optimization roadmap

Logio combined data analytics, layout redesign, and operational process optimization to create a realistic, implementation‑ready concept for the future state of SIGMA's production and logistics operations.

Current‑state analysis

Detailed mapping of all production and logistics processes, material flows, and key technology utilization. Historical data analysis identified trends, bottlenecks, and improvement opportunities.

Storage and production supply redesign

A more efficient organization of warehouse areas and production feeding was proposed, focused on reducing handling intensity. This included an assessment of suitable storage technologies and optimization of supply routes.

Supporting logistics process design

Optimization of adjacent logistics processes to ensure smooth, safe, and scalable operations. Proposals accounted for both the current state and future flexibility of the production system.

Variant evaluation and investment case

Several solution variants with different investment levels were prepared and compared in terms of operational impact, space utilization, and efficiency. A recommended variant was delivered with full economic justification.

Intralogistics & Material Flow

OPEX, CAPEX and ROI Calculations

Process Mapping & Analysis

Process Optimization

Impact

More space, smoother flows, room to grow

320 m² of production space freed

Consolidation and layout changes released production floor area for future expansion or operational improvements.

1,010 m² of warehouse capacity recovered

Reorganization and more efficient storage arrangements freed significant warehouse space.

10–20% shorter handling routes

Streamlined material flows and simplified internal logistics reduced unnecessary movement across the facility.

4–6 year investment payback

The recommended variant delivers a clear return on investment within a mid‑term horizon, depending on the chosen scope.

Hundreds of hours saved annually

Reduced preparation and handling times translate into substantial labor hour savings each year.

Scalable foundation for future growth

The new concept supports further production development without the need for major infrastructure investment.

The aim of the project from SIGMA was to optimise warehouse management and production capacities with regard to the ongoing revitalisation of the production hall. The analysis by Logio gave us answers to key questions, both in terms of production and storage capacities, and the need to adapt the hall in terms of the company's future development.

Ondřej Čepl

CFO, SIGMA group

Get more from your existing facility

If your production and logistics layout is holding back efficiency, we can help you find the hidden capacity. Let's talk about how a data‑driven optimization concept can unlock your next phase of growth.

420

By submitting, you agree to our Privacy Policy and allow Logio to contact you.

We tackled many supply chain challenges

Explore all case studies

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)

Show case study

Robotized battery sequencing for an automotive assembly line

Robotized battery sequencing cell with vision verification reduced manual handling risk and is ready for AGV integration. Business case projected a 3.5 year payback.

Verified picking with vision

Reduced manual handling

Proven economics