Installation of a new coating line and renovation of the production hall

Project Details

Project Management
Clarification of Interfaces Between Construction Trades and Technological Equipment
Planning and Implementation of Renovation Measures for the Entire Site
Space planning
Layout design in 2D and 3D
Preparation and evaluation of decision proposals
Support for Building Permits and Review of Contract Terms

Lightweight Material with Advanced Technology

For over twenty years, the factory planner HÖRMANN Rawema has been supporting Bharat Forge, the leading supplier of forged chassis and engine components, in its metal forming activities, particularly in forging. What does the layout of the forging facilities look like? What costs should be expected for technical building equipment? What automated process solutions are available? And what requirements must be met by the measurement technology? These are questions that will be answered. Bharat Forge relies above all on the factory planner’s expertise—from plant concepts to product implementation, we work together to develop efficient solutions.

For several years now, a key feature of this collaboration has been the consistent use of 3D planning. Since HÖRMANN Rawema, as the general planner, consistently consolidates data from multiple sources, standardized interfaces are integrated into the planning process alongside known data from established partners to provide the customer with a customized yet reliable plan.

HÖRMANN Rawema – The Factory Planner. Featured Project: Factory of the Future

3D Design for More Efficient Factory Planning

During the planning phase, HÖRMANN Rawema integrates architectural data—such as structural members and walls—with data on building services, such as cooling and ventilation. This data is then linked, for example, to the production facilities. All of this must result in a unified, efficient, and functional design during the planning phase and is therefore coordinated intensively with all parties involved. Based on the comprehensive 3D model, the factory planners then establish, for example, schedules and detailed coordination plans.

After the planning phase, HÖRMANN Rawema uses the models for the implementation phase to coordinate installation sequences with suppliers. Since many processes on the construction site take place sequentially, comprehensive on-site project management is also required to ensure optimal workflow on the construction site. For longer renovation projects, the factory planner has also been performing 3D modeling using 3D laser scans since 2015, which can also serve as a starting point for digitizing existing structures.

Factory of the Future

General planning is increasingly relying on comprehensive 3D planning to help customers better understand the planning process and to provide even more detailed insights into the process. “In the coming years, we will also enable our customers to collaborate with us on factory planning in virtual spaces,” said Holger Füssel, Managing Director of HÖRMANN Rawema.

To this end, HÖRMANN Rawema is expanding its expertise in Building Information Modeling (BIM) in collaboration with strong partners, participating in the development of the VDI guideline for BIM-based factory planning, and defining potential applications for augmented reality (AR) and virtual reality (VR) systems with a focus on collaborative work, and is working on the “AgilPlanBZ” research project to develop a flexible, adaptable factory for the production of fuel cells, with the goal of promoting efficient factory planning in the era of digitalization in manufacturing.

HÖRMANN Rawema – The Factory Planner. Featured Project: Smart Factory

Smart Factory Nominated for the Saxon Innovation Award

Digitalization and direct channels of information and communication—online and in real time—are transforming industrial production. The terms “Industry 4.0” and “Smart Factory” encompass the resulting novel, dynamic collaboration between people and technology within and between factories in a myriad of ways.

The potential for businesses is therefore just as great as the steadily growing range of individual and customized solutions available on the market. An important challenge for the factory planner HÖRMANN Rawema therefore lies in the logical selection of digital functionalities and the corresponding harmonization of data flows.

The nominees

With its Smart Factory, HÖRMANN Rawema made it into the top ten nominees for the 2019 Saxony Innovation Award.

To distinguish between general and broad visions, the company developed a smart factory demonstrator that allows current Industry 4.0 tools to be tested under industrial conditions and validated for their effectiveness and applicability.

To keep investment costs moderate and ensure the demonstrator’s intended portability, a model production system was configured in line with a high-tech, low-cost strategy. This system combines LEGO-like building blocks (e.g., conveyor belts, handling systems) and industrial components (e.g., laser stations, vibration/temperature sensors) via SIMATIC S7. Communication and database connectivity are handled via an OPC UA application. All transport and handling tasks are fully automated. Further expansion phases are in the planning stages.

Simulation

Reality

Featured Projects

HÖRMANN Rawema Engineering & Consulting GmbH is an innovative, manufacturer-neutral engineering firm specializing in the provision of technical planning services in the industrial sector, with a focus on production technologies and factory planning.

The engineering services cover the entire lifecycle of a factory, ranging from acting as the general planner responsible for the design of entire factories, through the engineering of individual production areas, processes, and systems, to reengineering and the resulting relocation projects.