System planning/tendering & specifications for mechanical processing at Bahntechnik Brand-Erbisdorf GmbH

Overview

Location: Germany, Saxony, Brand-Erbisdorf
Project duration: 3 months
 

HÖRMANN Rawema Engineering & Consulting GmbH supported Bahntechnik Brand-Erbisdorf GmbH in the systematic planning and tendering of production systems for mechanical processing. The project included the complete development of plant concepts from the initial requirements analysis to the cost estimate.

Project content

Determining the requirements for the plants

The specific requirements for the required plants were systematically determined and documented on the basis of detailed production and process times.

Creating a plant layout in 2D

The visTABLE software was used to create a detailed 2D layout of the production plant, taking into account all relevant production areas and material flows.

Creation of a specification sheet template

A standardized specification sheet template was developed to ensure uniform tender documents for different plant types.

Transferring the information into specification sheets

The determined plant data was systematically transferred into detailed specification sheets, with a particular focus on mechanical processing.

Supplier research and preliminary enquiries

A comprehensive market analysis was carried out and qualified suppliers for the various system components were identified and enquired about.

Testing the technical feasibility

The technical feasibility of the planned system concepts was validated and evaluated based on the supplier feedback.

Creation of rough cost estimates

Founded cost estimates were created for all planned systems to provide a solid basis for investment decisions.

Advantages of our solution

• Systematic planning approach: Complete coverage of all planning phases from requirements analysis to cost estimation
• Professional software solutions: Use of proven tools such as visTABLE for precise layout planning
• Market knowledge: Comprehensive supplier network for optimal plant solutions
• Risk minimization: Early feasibility check prevents costly wrong decisions
   

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Conversion/restructuring maintenance and refurbishment of an existing hall

Overview

Location: Germany, Saxony, Brand-Erbisdorf
Investment amount: approx. 500.000 €
Project duration: 10 months

HÖRMANN Rawema Engineering & Consulting GmbH took on the comprehensive general planning for the restructuring and refurbishment of an existing hall at Bharat Forge Aluminiumtechnik GmbH. The project included both the new technical planning of the maintenance processes and the structural refurbishment of the existing hall structure.

Project content

Creation of a machine list including determination of required connections and their power

Detailed recording of all machines and systems with precise determination of the required energy connections and power requirements for optimal integration into the new hall structure.

Creation of a facility layout in 2D and 3D in visTABLE

Development of a consistent factory planning concept with modern 3D visualization tools for optimal use of space and efficient workflows in maintenance.

Planning and evaluation of the structural implementation and technical building equipment, preparation of the necessary drawings

Comprehensive technical building equipment planning with detailed evaluation of the structural measures and preparation of all necessary implementation drawings.

Evaluation of existing connections and existing buildings

Structural analysis of the existing building fabric and evaluation of the integration possibilities of existing connections and infrastructures.

Production of cost estimates and schedules

Development of realistic cost calculations and detailed project schedules for on-time and on-budget implementation.

Execution of service phases 1 - 8 for construction and technical building services

Complete project management from basic evaluation to project management in accordance with HOAI for both construction and technical building services.

Interface coordination between the planning participants

Professional coordination of all specialist planners and trades involved to ensure smooth project execution.

Conducting construction meetings

Regular coordination and agreement with all project participants through structured construction meetings during the entire implementation phase.

Advantages of our solution

• Comprehensive general planning: Complete project management from a single source from the initial idea to completion
• Modern 3D planning tools: Use of visTABLE for precise visualization and optimal use of space
• Inventory optimization: Professional integration of existing structures to minimize costs
• On-time implementation: Structured project management with detailed scheduling and cost planning
   

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3D-Scan & layout planning for the relocation of packaging systems at AESICA Pharmaceuticals GmbH

Overview

Location: Germany, Saxony / North Rhine-Westphalia (Zwickau / Monheim am Rhein)
Scope of relocation: 2 systems + peripherals
Project duration: 2 months
Production/laboratory space: approx. 500 m²

HÖRMANN Rawema Engineering & Consulting GmbH supported AESICA Pharmaceuticals GmbH with the complex relocation of packaging systems between two sites. By using state-of-the-art 3D scanning technology and systematic layout planning, a safe and efficient plant relocation was realized.

Project content

3D laser scanning to take stock of both sites

Using high-precision 3D laser scanning technology, a detailed inventory of both sites was carried out to create an exact starting point for the relocation planning.

Drawing comparison and 3D modeling

Existing drawings were compared with the scan data and precise 3D models of facilities, buildings, logistics areas and interfaces were created.

Representation of functional and logistics areas

All relevant areas were systematically recorded and visualized, including ancillary areas, workstations and the necessary peripherals.

Safety distance check and collision check

The 3D point cloud was used to check safety distances, accessibility and path widths, and a comprehensive collision check was carried out.

Layout workshops for joint specification

In interdisciplinary workshops, the layouts were specified and optimized together with the client.

Determination and description of the target layout

The final target layout was defined and documented in detail in order to create a clear basis for implementation.

Support with the relocation concept

The project team provided support in developing a well thought-out relocation concept for smooth implementation.

Advantages of our solution

• Precise 3D technology: Highly accurate as-built survey using state-of-the-art laser scanning methods minimizes planning risks and ensures accurate results.
• Systematic approach: Structured project management from the inventory to the final relocation concept ensures predictable and reliable implementation.
• Interdisciplinary collaboration: Layout workshops enable the optimal integration of all requirements and ensure customer-specific solutions.
• Collision check and safety: Comprehensive check of all safety aspects and accessibility prevents costly rework.
   

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Factory feasibility study for an innovative thermal insulation retrofit product for windows at Mackinac GmbH / Mackinac Technology Company

Overview

Location: Dresden, Germany / Michigan, USA
Project year: 2019

HÖRMANN Rawema Engineering & Consulting GmbH conducted a feasibility study in 2019 for the factory to manufacture an innovative retrofit product for the thermal insulation of windows. The aim was to dimension processes, space, resources and costs in a resilient manner and to define a rough layout ready for implementation.

Project content

Data collection and structuring

Systematic collection and structuring of all relevant technical and organizational data. Clean data basis as the basis for design and evaluation.

Process diagram and material flow

Creation of a process diagram and presentation of the material flows along the value chain. Clear interfaces and delivery logics for stable processes.

Space calculation

Calculation of the required production, logistics and ancillary areas. Orientation towards efficient plant structure and future expansions.

Dimensioning of machines, equipment and logistics

Dimensioning of production machines and equipment as well as logistics equipment. Efficient capacities and buffers to ensure throughput and deadlines.

Personnel requirements

Determination and dimensioning of personnel requirements per area and shift model. Transparent basis for resource planning and costs.

Layout design (rough layout in 2D/3D)

Development of a rough layout in 2D and 3D. Visualization of installation areas, path relationships and media connections.

Cost framework estimate

Deduction of a cost framework based on the dimensions. Decision-relevant key figures for further project phases.

Advantages of our solution

• Decision security: Well-founded dimensioning and cost framework create a clear basis for investment decisions.
• Planning certainty: Process diagrams, material flows and area calculations reduce technical and operational risks.
• Capacity clarity: Well-designed machine, logistics and personnel resources ensure performance and cycle stability.
• Transparency: 2D/3D- rough layouts make interfaces, routes and areas visible and comparable.
• Scalability: Area and resource models support subsequent expansion stages and variants.
   

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Digitalization/retrofit of a ball grinding machine at KRS - SEIGERT GmbH

Overview

Location: Barchfeld, Thuringia, Germany
Project duration: 2017-2020; implementation since mid-2019
Production/logistics area: approx. 16.000 sqm
Research project: Plug & Control

HÖRMANN Rawema Engineering & Consulting GmbH implemented the digitalization and retrofit of a ball grinding machine for KRS - SEIGERT GmbH. The aim was to build a scalable data and visualization platform, integrate measurement data from existing sources and provide meaningful dashboards for operational control and decision support.

Project content

IT infrastructure and server architecture

Setting up the information technology (IT)- infrastructure with servers for InfluxDB (time series database), Grafana and web service. Standardized architecture as the basis for data acquisition and evaluation.

Worker terminal and measuring station integration

Provision of a worker terminal with measuring station and connection of the measuring device. Development of an active Excel-sheet for simple data acquisition and deviceäinteraction.

Data acquisition and interfaces

Recording of information from the Open Platform Communications (OPC)- server. Import of Excel-sheets with manual measurements to merge all data sources.

Business intelligence and analysis

Development of business intelligence (BI)- services in Python/Windows. Automated preparation, analysis and calculation of relevant key figures for the store floor.

Dashboards and visualization

Design of Grafana- dashboards with access to InfluxDB. Real-time-visualization of statesänden, trends and alerts forütransparent processes.

Administration and operation

Workshops on administration and handling of the system. User empowerment and stable operating processes through clearly defined roles and routines.

Advantages of our solution

• Real-time transparency: Grafana- dashboards with InfluxDB show live and comprehensible statuses, trends and KPIs.
• Decision support: Python-based BI-services provide reliable evaluations forquick, well-founded decisions.
• Gentle retrofit: Open interfaces (OPC, Excel) modernize existing systems without in-depth interventions.
• Scalability: Standardized IT-architecture and modular services enableöpossible extensions to additional machines.
• Operational reliability: Training and clear administration concepts strengthen expertise and ensure stable, continuous operation.
   

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Process description and operating manual for indoor e-kart system at BRP - Rotax GmbH, MAX Dome in Linz

Overview

Location: Linz, Austria
Project duration: 2 months
Area to be covered: approx. 4.300 sqm (≈ 35 rooms, 550 objects)

HÖRMANN Rawema Engineering & Consulting GmbH successfully created the process description and operating manual for an indoor--E--Kart- system. The aim was to fully document the user experience and processes, derive construction objectives and create a reliable basis for operation and future franchise implementations.

Project content

Describing the user experience

Clear description of the intended user experience. Standardized guidelines for visitor guidance, service points and operating processes.

Complete process mapping and time evaluation

Mapping of all management, core, ancillary and franchise processes, including time evaluation. Transparent processes as the basis for control and scaling.

Identifying construction objectives

Determining general construction objectives from process and safety requirements. Orientation for planning, equipment and space organization.

Personnel matrix, room and equipment list

Creation of a detailed personnel matrix and a complete room and equipment list. Clear allocation of resources and responsibilities for operations.

Franchise derivations

Development of a schedule, safety, maintenance and cleaning concept as well as responsibilities according to RASIC (Responsible, Accountable, Support, Informed, Consulted). Practical guidelines for future franchisees.

Operations manual

Structured preparation of all content in the operations manual. Comprehensible chapter structure, clear responsibilities and robust checklists.

Advantages of our solution

• Process clarity: Standardized descriptions with time evaluation increase transparency and controllability.
• Operational maturity: Operating manual, security and service concepts ensure a reliable start and ongoing operation.
• Scalability: Franchisable derivations enable reproducible rollouts at additional locations.
• Resource transparency: Personnel matrix and room/equipment list create a clear basis for resource planning and procurement.
• Reliability of implementation: Construction objectives and scheduled measures reduce risks and accelerate decisions.
   

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Layout planning for press line and plant expansion at HÖRMANN Automotive

Overview

Location: Bánovce nad Bebravou, Slovakia
Production/logistics area: approx. 11.600 sqm
Press line: five individual presses
Scrap conveying system: Shaft and system especially for the press line

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the layout planning for a press line and the plant expansion for HÖRMANN Automotive. The aim was to design a resilient pit, scrap conveyor system and machine installation and to define a layout optimized for space and material flow for the existing hall and expansion.

Project content

Press line pit planning

Design and planning of the press pit for five individual presses. Geometry, accesses and interfaces designed for safe assembly and maintenance.

Scrap conveyor shaft and system

Planning of a scrap conveyor shaft and the associated system specifically for the press line. Integration into layout and material flow with clear delivery logics.

Machine installation in the existing production hall

Layout planning for optimized machine installation. Short distances, clear transfer points and space-saving arrangement to stabilize processes.

Layout of hall extension (approx. 11,600 m²)

Development of the extension layout with a focus on short material flows, space efficiency and flexibility. Coordination of routes, storage areas and logistics zones.

Material flow and flexibility concept

Definition of route relationships, buffer areas and delivery zones. Focus on flexibly scalable variants and fast changeovers.

Advantages of our solution

• Space efficiency: Optimized machine set-up and expansion layout save space and increase usable floor space.
• Material flow quality: Short distances and clear delivery logics shorten throughput times and stabilize operations.
• Operational safety: Sophisticated pit planning and integrated scrap conveyor system facilitate assembly, maintenance and safe work.
• Future-proof: Flexible layouts support variant changes and gradual expansion options.
• Readiness for implementation: Precise pit and conveyor system design creates a clear basis for construction and installation.
   

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Logistics process planning seat production Mercedes G-Class (MOPF) at Magna Steyr Fahrzeugtechnik AG & Co. KG

Overview

Location: Graz, Austria
Focus: Seat production, logistics planning, project coordination, layout planning

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the logistics process planning for the seat production of the Mercedes G- Class (MOPF) at Magna Steyr Fahrzeugtechnik AG & Co. KG. The aim was to reliably coordinate processes and interfaces, plan warehouses and sequencing in a resilient manner, create layouts and evaluate and calculate integration-capable logistics concepts - including AGVs/ AGVs -.

Project content

Project coordination between suppliers and Magna logistics

Structured coordination between suppliers and Magna's logistics departments. Clear responsibilities and information flows to ensure timely and high-quality implementation.

Process planning and internal planner coordination

Development of process planning and coordination of internal planners. Uniform premises and processes for stable material and information flows.

Warehouse planning and optimization

Design of warehouse structures and optimization of storage areas, buffers and access logics. Reduction of travel times and increase in inventory quality.

Sequencing processes and scopes

Planning of sequencing processes including scope definition. Ensuring cycle and variant-compliant delivery to seat assembly.

Layout planning

Creation of layouts with clear path relationships, transfer points and delivery zones. Transparent basis for implementation and IT-connection.

Integration variants for AGVs/ATVs

Evaluation of integration variants for automated guided vehicles (AGVs) and automated guided vehicles (AGVs). Derivation of requirements for infrastructure, IT and operations.

Evaluation and calculation of logistics concepts

Comparison and calculation of various logistics concepts. Decision preparation based on performance, costs and integration effort.

Advantages of our solution

• Interface clarity: Structured coordination of suppliers, logistics and internal planners reduces risks and speeds up coordination.
• Process stability: Clearly planned sequencing and storage processes ensure cycles and supply for seat production.
• Transparency: Clear layouts and defined premises create a comprehensible basis for implementation and IT- integration.
• Decision security: Evaluated and calculated logistics concepts enable reliable investment and operating decisions.
• Integration capability: AGV/FTF- variants with infrastructure and IT requirements facilitate scalable, future-proof operation.
   

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3D laser scanning for the integration of a conveyor system at ZKW Lichtsysteme GmbH

Overview

Location: Wieselburg an der Erlauf, Austria
Scanning area: approx. 10,000 m²

HÖRMANN Rawema Engineering & Consulting GmbH has successfully implemented 3D laser scanning for the integration of a conveyor system for ZKW Lichtsysteme GmbH. The aim was to precisely capture existing areas, provide views and sections from the scan data and transfer a processed point cloud to viewer-software for collision checks and measurements.

Project content

3D laser scanning production hall (partial areas)

High-resolution recording of the relevant hall zones over approx. 10,000 square meters. Basis for dimensionally accurate planning and collision-free integration of the conveyor system.

Views and sectional views

Creation of views and sectional views from the 3D- scan data. Clear visualization oföhangs, routes and fixtures.

Point cloud preparation and transfer

Preparation of the point cloud with structuring for further use. Transfer to viewer software for direct use.

Collision check between existing and planned conveyor system

Provision of data for collision check between existing and planned conveyor system. Early detection and avoidance of installation conflicts.

Measurement support

Use of the processed point cloud for reliable measurements. Ensure dimensional accuracy for detailed planning and tendering.

Advantages of our solution

• Precision: High-resolution scans provide exact as-built data for planning and integration.
• Collision-free: Viewer--compatible point clouds enableöheavy, reliable collision checks.
• Transparency: Views and sections make routes, heights and interfaces clearly visible.
• Efficiency in layoutß: Digital point clouds shorten layoutütimes and increase maötainability.
• Planning reliability: Structured dataütransfer supportsüfast decisions and reduces rework.
   

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