3D laser scanning of factory premises and production halls at TRIMET Automotive Holding

Overview

Location: Harzgerode, Saxony-Anhalt, Germany
Scanning area: approx. 100,000 m²

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the 3D laser scanning of factory premises and production halls for TRIMET Automotive Holding. The aim was to create an up-to-date 2D plant layout and provide reliable 3D models of the halls, including machinery and equipment.

Project content

3D laser scanning of the plant site and halls

High-resolution mapping of the plant site and production halls covering approx. 100,000 square meters. Precise point clouds as the basis for layout and modeling.

Current 2D plant layout

Creation of a current 2D plant layout. Clear visualization of areas, path relationships and functional areas.

3D computer-aided design (CAD)

Hall modelling Modelling of the production halls in 3D. Structured geometries for a dimensionally accurate and consistent planning view.

3D CAD models of machines and systems

Capture and modeling of machines and systems. Standardized level of detail for transparent interfaces and subsequent further planning.

Advantages of our solution

• Precision: 3D laser scans provide exact as-built data and increase the dimensional accuracy of layouts and models.
• Transparency: Up-to-date 2D factory layouts and 3D models make surfaces, paths and interfaces visible at an early stage.
• Planning reliability: Consistent data bases make decisions easier and reduce rework during implementation.
• Reusability: Structured 3D models support variant creation and downstream engineering steps.
   

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Planning support for the conversion of the ColdEnd at Novelis Deutschland GmbH

Overview

Location: Nachterstedt/Seeland, Germany
Project duration: 12 months

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the planning support for the conversion of the ColdEnd. The aim was to precisely design piping and steelwork layouts, to technically clarify measurement systems including explosion protection and to support the implementation by coordinating suppliers and construction sites on schedule.

Project content

3D layout planning for pipe routing and steelwork

Development of the three-dimensional (3D) layout planning for pipe routing and steelwork. Clear routes, media paths and construction points for collision-free integration.

As-built survey using 3D laser scanning

Recording of existing pipes using 3D laser scanning. Precise geometric data as a basis for planning, comparison and variant evaluation.

Technical clarification of the piping concept

Development and clarification of the technical requirements of the piping system. Ensuring functionality and interface compatibility.

Measurement systems and sensors including explosion protection

Support with the technical development of the necessary measurement systems and measurement sensors including explosion protection. Specifications for measuring points and their positioning.

2D layout planning of the piping system

Two-dimensional (2D) layout planning of the piping system including cyclone installation areas and positioning of the measuring points. Transparent representation of path relationships and connections.

Supplier management

Creation of requirement specifications and specifications as well as coordination of suppliers. Clarified interfaces and documented requirements for smooth implementation.

Construction site organization during implementation

Organization of the construction site during the implementation phase. Structured processes and clear responsibilities on site.

Advantages of our solution

• Collision-free: 2D/3D layouts and 3D laser scanning ensure consistent planning and avoid paving conflicts.
• Interface safety: Technical clarification of the piping concept and coordinated measuring systems reduce risks at media and construction interfaces.
• Explosion protection: Consideration of safety requirements increases operational safety and facilitates approvals.
• On-time implementation: Supplier management and construction site organization stabilize milestones and reduce rework.
• Transparency: Requirement specifications and specifications create a clear basis for decision-making and implementation.
   

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Expansion of car body warehouse (high-bay warehouse) at Magna Steyr Fahrzeugtechnik

Overview

Location: Graz, Austria
Project duration: 10 months
Capacity expansion: Doubling of storage capacity
Conveyor technology: Replacement/expansion of approx. 200 elements

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the expansion of the car body high-bay warehouse at Magna Steyr Fahrzeugtechnik. The aim was to double the storage capacity, comprehensively modernize the connecting conveyor technology and reliably accompany the implementation through to commissioning (IBN).

Project content

Doubling storage capacity

Expansion of the high-bay warehouse with three new aisles and suitable storage and retrieval machines. High-performance expansion for stable supply to the assembly areas.

Replace and expand conveyor technology

Replacement and expansion of the connecting conveyor technology with approx. 200 elements. Clear interfaces and coordinated delivery logics for smooth material flows.

Concept and detailed planning

Development of robust concept and detailed planning. Definition of layout, transfer points and media connections to ensure implementation.

Tendering and contract award support

Preparation of tender documents, technical clarifications and structured bid evaluation. Contract award support to ensure quality, deadlines and costs.

Site supervision and coordination

Coordination of on-site implementation with trade interfaces. Progress monitoring and quality assurance up to functional release.

Commissioning (IBN) and acceptance preparation

Support for IBN with test plans and documentation. Preparation of acceptance with verification of performance and safety parameters.

Advantages of our solution

• Capacity increase: Three new aisles and storage and retrieval machines double the storage capacity and increase security of supply.
• Process stability: Modernized conveyor technology with around 200 elements reduces disruptions and shortens throughput times.
• On-time implementation: Structured planning, tendering and construction site coordination ensure milestones through to acceptance.
• Transparency: Precise concept and detailed planning creates clear interfaces and a reliable basis for decision-making.
• Ready for implementation: IBN support and acceptance preparation accelerate the start of production and ensure quality.
   

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Planning / realization of a ventilation system at PCW GmbH

Overview

Location: Eilenburg, Saxony, Germany
Project duration: 2018 - 2020
Investment amount: over €500 thousand

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the planning and realization of a ventilation system for PCW GmbH. The aim was to precisely record the existing building, evaluate variants technically and economically and coordinate the implementation through to acceptance on schedule.

Project content

As-built survey and 3D laser scanning

Data recording of the existing building and 3D laser scanning. Precise geometric data as the basis for planning and collision avoidance.

Concept planning and variants with cost estimates

Development of technical implementation solutions in several variants with cost estimates. Decision preparation through clear service and interface descriptions.

Supply air/exhaust air/cooling system planning (3D)

Planning of supply air, exhaust air and cooling generation including 3D planning. Focus on efficient media routing and maintenance-friendly integration.

Performance parameters and design

Determination of the technical system parameters: Volume flow rate 60,000 m³/h each, cooling capacity approx. 300 kW. Dimensioning to ensure performance and energy efficiency.

Tendering and awarding

Drafting the tender documents and conducting bidder interviews. Structured tender review and award to ensure quality and costs.

Execution: coordination and monitoring

Coordination and monitoring of execution on site. Schedule, quality and interface control through to functional release.

Supplier and interface management

Active management of suppliers and technical interfaces. Ensuring smooth collaboration between all building services engineering trades.

Advantages of our solution

• Planning reliability: Precise inventory data, variant concepts and cost estimates create a reliable basis for decision-making.
• Performance: Design of supply air, exhaust air and cooling with defined parameters ensures climate quality and energy efficiency.
• On-time implementation: Structured tendering, awarding and on-site management stabilize milestones until acceptance.
• Interface clarity: Professional supplier and interface management reduces technical risks and rework.
• Transparency: Complete documentation and clear records facilitate approvals and strengthen compliance.
   

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Bogie production planning at Siemens

Overview

Location: Graz, Austria
Production area: approx. 9,600 square meters
Focal points: Production, welding processes, material handling

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the production planning of a bogie for Siemens. The aim was to design fixtures and loading in a variant-capable manner, optimize material flows and layout and provide a reliable basis for investment, time and personnel.

Project content

Fixture concepts (4 variants)

Concepts for fixtures in four variants. Evaluation according to stability, set-up effort and integration capability in the process.

Automatic vs. manual feeding

Comparison of automatic and manual feeding in terms of performance, ergonomics and cost-effectiveness. Derivation of the preferred solution for series use.

Hall layout and material positioning

Hall layout for chassis production and dimensioning of the material positioning areas. Clear path relationships and buffer concepts for stable processes.

Process sequences for long beams and center connectors

Creation of process flow diagrams for long beams and center connectors. Transparent sequence and transfer points as a basis for cycle design and control.

Economics and investment framework

Economics analysis and summary of the necessary equipment and investment volume. Comparison of the variants with cost and benefit assessment.

Proposal for award of contract

Deduction of a proposal for award of contract based on technical criteria and economic efficiency. Preparation of a structured tendering and decision-making process.

Time and manpower requirements

Determination of production time and manpower requirements. Dimensioning for high-performance, cost-efficient operation.

Advantages of our solution

• Decision certainty: Variant comparison, profitability assessment and contract award proposal create a clear basis for procurement and implementation.
• Increased efficiency: Optimized hall layout, material arrangement and suitable loading shorten throughput and set-up times.
• Clarity of investment: Transparent compilation of the equipment and investment volume facilitates budgeting and prioritization.
• Process transparency: Process flow charts make sequences, handovers and cycles traceable and controllable.
• Capacity planning: Precise time and personnel determination supports a resilient, scalable production organization.
   

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MTM analyses of final assembly and production at Liebherr-Hausgeräte Lienz GmbH

Overview

Location: Lienz, Tyrol, Austria
Project duration: 2020-2021
Areas: Final assembly, final assembly islands

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented MTM analyses in final assembly and production for Liebherr-Hausgeräte Lienz GmbH. The aim was to document workflows transparently, evaluate them in terms of time management and provide standardized process modules for variant planning and optimization.

Project content

Data acquisition in assembly areas

Description of the work sequences with the parts to be assembled, documentation of the individual work steps and creation of a workstation overview. Consistent data basis for time management evaluation.

MTM time determination and TiCon documentation

Detailed determination and listing of times according to Methods-Time Measurement - Universal Analysis System (MTM-UAS) in TiCon. Complete assignment of times to work steps for comparability and evaluation.

Product-neutral MTM process modules

Development of product-neutral MTM process modules. Reusable standards for rapid evaluation of new or changed processes.

Variant creation based on reference analysis

Generation of product variants based on the reference analysis of type representatives. Structured transfer of time and process data to variants.

Optimization approaches

Identification of possible optimization approaches in workflow, ergonomics and cycle design. Prioritized measures as a basis for implementation and monitoring.

Advantages of our solution

• Time transparency: MTM UAS times in TiCon make processes measurable and comparable.
• Standardization: Product-neutral process modules accelerate the evaluation and rollout of new variants.
• Variant clarity: Reference analyses enable reliable time and process transfers to product variants.
• Efficiency potential: Concrete optimization approaches support cycle stability and ergonomic improvements.
• Planning fundamentals: Clean data collection and structured documentation provide a reliable basis for decisions.
   

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Digitization consulting, 3D laser scanning, BIM at BRP Rotax GmbH & Co KG

Overview

Location: Gunskirchen, Upper Austria, Austria
Project duration: 4 months
Focus: Digitalization, Smart Factory, Building Information Modeling (BIM), 3D-Modelling

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented digitalization consulting, 3D laser scanning and BIM-support for BRP Rotax GmbH & Co KG. The aim was to prepare digital initiatives in a structured manner, involve stakeholders across all management levels and create a reliable basis for planning using precise as-built data and layout models.

Project content

Sequence of events

Creation of a detailed sequence of events as a process specification for digital measures. Clear responsibilities and milestones for plannable implementation.

Media partner coordination

Coordination of media partners for coordinated communication and technical provision. Ensuring consistent content and formats for internal and external stakeholders.

Potential analysis of planned measures

Initial potential analysis of the planned digitalization measures. Evaluation of benefits, costs and feasibility as a basis for prioritization.

Assessment workshops

Planning of assessment workshops with relevant stakeholders. Structured agenda and target definition for resilient results.

Script for media implementation

Creation of a script for the media implementation of digital initiatives. Consistent messages and visualizations for decision-makers and employees.

Questionnaire for management levels

Development of a questionnaire to integrate different management levels into digital change processes. Recording of requirements, expectations and hurdles.

3D laser scanning and layout modeling

Inventory using 3D laser scanning and layout modeling. Precise data basis to support Smart-Factory-initiatives and BIM-processes.

Advantages of our solution

• Decision-making basis: Sequence of events, workshops and potential analysis create a reliable basis for prioritization and implementation.
• Stakeholder alignment: Script and questionnaire ensure a common understanding and promote active participation across all levels.
• Data and model quality: 3D- laser scans and layout models increase accuracy and predictability forü digital transformation projects.
• Speed of implementation: Coordinated media partners and clear formats speed up communication, preparation and implementation.
   

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Planning / realization of new coating plant and hall reconstruction at HÖRMANN Automotive Eislingen

Overview

Location: Ebersbach, Baden-Württemberg, Germany
Project duration: 21 months
Expansion of production area: 45 %

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the planning and realization of a new coating plant as well as the hall reconstruction for HÖRMANN Automotive Eislingen. The aim was to clarify interfaces, manage refurbishment measures across the entire site and design areas and layouts in a resilient manner.

Project content

Project management

Continuous project management across all phases. Clearly defined processes and responsibilities ensure deadlines, quality and budget.

Clarification of interfaces between construction trades and technological equipment

Structured clarification of interfaces between construction trades and technological equipment. Minimization of technical risks and smooth integration of the plant.

Refurbishment measures for the entire site

Planning and implementation of the refurbishment measures for the entire site. Coordination of the construction phases to reduce disruptions to ongoing operations.

Space dimensioning

Determination of space requirements for production, logistics and infrastructure. Orientation towards efficient plant structure and future expansions.

Layout design in 2D and 3D

Development of layouts in two dimensions (2D) and three dimensions (3D). Transparent visualization of set-up areas, path relationships and media routing.

Creating and evaluating a decision proposal

Creating a decision proposal with variant evaluation. Sound basis for management approvals and investment decisions.

Building permit and contract review

Preparation of the building permit and review of the contract terms. Assurance of legal requirements and reliable delivery scopes.

Advantages of our solution

• Interface clarity: Coordinated construction and plant interfaces reduce technical risks and rework.
• Planning reliability: Well-founded area dimensioning and 2D/3D layouts create a reliable basis for decision-making and implementation.
• Date stability: Consistent project management and coordinated construction phases ensure milestones in the existing building.
• Permit security: Structured preparation for planning permission speeds up procedures and increases compliance.
• Capacity increase: Expansion of the production area by 45% increases performance and supports growth.
   

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Relocation planning and coordination of overall production at HÖRMANN Automotive Penzberg and Slovakia

Overview

Location: Penzberg, Bavaria, Germany / Slovakia 
Project duration: 17 months + follow-up projects 
Project costs: approx. 74.3 million €

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the relocation planning and coordination of the entire production from HÖRMANN Automotive Penzberg to HÖRMANN Automotive Slovakia. The aim was to coordinate plant and equipment relocations with OEM end customers, secure deadlines and make it possible to plan the production start-up at the target location.

Project content

Relocation of entire production scopes

Planning and management of the transfer of mechanical production and assembly from Penzberg to Slovakia. Structured sequencing to ensure quality and deadlines.

Relocation packages

Support and planning Definition, prioritization and development of relocation packages. Clear content, milestones and resources for each package.

Relocation of plant and equipment

Coordination and agreement of the necessary relocation of plant and equipment. Interface clarification of dismantling, transportation, assembly and commissioning.

OEM end customer coordination

Coordination with the original equipment manufacturers (OEMs) involved - MAN, Daimler, Scania, John Deere and Meiller. Clarification of requirements, handover points and deadlines.

Scheduling and status tracking

Scheduling and planning across all packages. Ongoing tracking of the relocation status and assurance of plan fulfillment.

Information preparation and reporting

Processing of decision-relevant information. Regular reporting to stakeholders with transparent key figures.

Advantages of our solution

• End-to-end control: Consistent planning and coordination from dismantling to commissioning reduces risks and downtime.
• Timeline clarity: Binding scheduling and status tracking ensure milestones over 17 months and in follow-up projects.
• Interface coordination: Coordinated system, equipment and OEM interfaces increase quality and reliability.
• Transparency: Structured information preparation and reporting create traceability and quick decisions.
• Investment security: A clear overview of project costs of around €74.3 million supports budget adherence and prioritization.
   

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Installation of intermediate level and new construction of engine sequencer, Plant 3/Building 20 at Porsche AG

Overview

Location: Zuffenhausen, Baden-Württemberg, Germany
Project duration: 2017-2018
Construction costs: approx. 15 million euros

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the installation of an intermediate level and the construction of a new engine sequencer in Plant 3/Building 20 for Porsche AG. The aim was to implement the measures on schedule during ongoing operations, minimize disruptions and prepare acceptances in a plannable manner.

Project content

General planning

Consistent general planning across all relevant trades. Clear principles and processes as the basis for implementation in existing buildings.

Dismantling of existing facilities

Planning and implementation of selective dismantling. Ensuring occupational safety and adherence to deadlines.

Scheduling and coordination ("non-operating time")

Fine scheduling and coordination of the conversion measures in the "non-operating time" corridors. Minimization of production interruptions through coordinated time windows.

Compact construction during operation

Design and implementation in compact construction. Minimal disruption to adjacent, ongoing production.

Realization in several construction phases

Structured construction phases for gradual implementation. Ensuring access, safety and quality for each section.

Construction supervision and coordination, supplier and start-up management

Continuous construction supervision and coordination of trades. Control of suppliers and start-up management up to functional release.

Acceptance

Preparation and execution of acceptance tests. Proof of the required performance and safety parameters.

Advantages of our solution

• Deadline reliability: Detailed planning and coordination in "non-operating time" ensure milestones during ongoing operation.
• Operational stability: Compact construction methods and section-by-section implementation minimize disruptions to production.
• Quality assurance: Continuous construction monitoring and clear acceptance criteria increase execution quality.
• Transparency: General planning and coordinated processes create clear responsibilities and a basis for decision-making.
   

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