Rescheduling of the exhaust air system of a production area at Novelis Sheet Ingot GmbH

Overview

Location: Nachterstedt plant, Saxony-Anhalt, Germany
Project duration: 12 months
Focus: Inventory, 3D scan, piping redesign, system planning, project management

HÖRMANN Rawema Engineering & Consulting GmbH implemented the redesign of the exhaust air system of a production area at the Nachterstedt plant with the aim of measurably improving flow behavior, safety functions and reliability and ensuring implementation through to final acceptance.

Project content

Exhaust air system analysis and improvements

Analysis of the existing exhaust air system and derivation of targeted improvements in terms of flow behavior, safety functions and reliability. Reliable basis for replanning and implementation.

3D laser scan of existing ducts

Inventory of the ductwork using 3D laser scanning. Precise recording of geometries and interfaces as a basis for planning and collision checks.

CFD flow calculation

Calculation of flow resistances using computational fluid dynamics (CFD). Evaluation of pressure losses and power reserves for designing the new pipe routing.

3D pipeline redesign

Redesign of the pipeline routing in 3D. Optimized routes, cross-sections and installations to improve throughput and operational reliability.

Specification of measures and supplier selection

Specification of the conversion measures with clear descriptions of services and interfaces. Structured supplier selection and support through to commissioning.

On-site planning and monitoring

Planning and monitoring of the conversion measures on site. Schedule, quality and interface coordination through to functional approval.

Final acceptance and documentation

Execution of the final acceptance with proof of performance. Complete documentation as a basis for operation, maintenance and subsequent adjustments.

Advantages of our solution

• Flow efficiency: CFD-supported design reduces flow resistance and stabilizes exhaust air performance.
• Operational safety: Improved safety functions and quality-assured implementation increase reliability and availability.
• Transparency: 3D scanning and 3D replanning make pipe routing, installations and interfaces clearly comprehensible.
• On-time implementation: Precise specification of measures, supplier management and on-site monitoring reduce risks and rework.
• Documentation clarity: Final acceptance and complete documentation provide evidence and auditability for operation.
   

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New construction of an unpacking and used sand processing plant for casting/sand separation for large castings at Caterpillar Castings Kiel GmbH

Overview

Location: Kiel, Schleswig-Holstein, Germany
Project duration: 8 months
Scope of plant: Unpacking and used sand processing plant for casting/sand separation for large castings

HÖRMANN Rawema Engineering & Consulting GmbH successfully supported the construction of a new unpacking and used sand processing plant for casting/sand separation for large castings. The aim was to ensure that procurement, implementation and commissioning were technically and economically sound and that the required performance parameters were demonstrably achieved.

Project content

Tender documents (specifications and functional specifications)

Development of precise specifications and functional specifications as the basis for the supplier inquiries. Clear service and interface descriptions ensure comparability.

Solicitation of offers and supplier management

Structured solicitation of offers with technical and commercial comparison. Management of supplier communication and derivation of a reliable selection.

Supply and service contract

Support in drawing up a supply and service contract. Assurance of deadlines, quality and warranty requirements.

Pre-acceptance at the supplier

Conducting pre-acceptance tests to validate functionalities. Early validation of key performance features prior to assembly.

Assembly coordination and monitoring

Coordination of assembly processes and monitoring of execution. Clarification of interfaces and quality assurance up to functional release.

Commissioning, monitoring and proof of performance

Supervision of commissioning with test plans and documentation. Proof of the required performance parameters as the basis for acceptance and operation.

Advantages of our solution

• Procurement security: Precise tenders and structured bid comparisons reduce cost and quality risks.
• On-time implementation: Contract clarity, pre-acceptance and installation coordination stabilize milestones and start dates.
• Quality assurance: Monitoring of installation and commissioning reliably ensures functionality and performance.
• Transparency: Complete documentation and proof of performance create a clear basis for decision-making and auditability.
• Operational readiness: Coordinated interfaces and tested performance parameters enable a fast, stable production start-up.
   

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Logistics concept for a production line for processing stainless steels at Outokumpu Nirosta GmbH

Overview

Project duration: 2 months
Area: 13,475 square meters

HÖRMANN Rawema Engineering & Consulting GmbH successfully developed a logistics concept for a production line for processing stainless steels for Outokumpu Nirosta GmbH. The aim was to present the plant structure and material flows transparently, to dimension areas and means of transport in a resilient manner and to define a preferred variant with a detailed layout.

Project content

Plant structure and logistics planning

Conception of the plant structure and internal logistics. Focus on short distances, stable buffers and clear transfer points.

Data collection and planning assumptions

Systematic collection of relevant data and definition of planning assumptions. Clean data as a basis for design and evaluation.

Process and material flow representation

Visualization of process and material flows along the value chain. Clear interfaces and delivery logics for smooth processes.

Dimensioning of storage areas and means of transport

Calculation of storage, transport and ancillary areas. Determination of the types and number of means of transport to ensure efficient operation.

Pre-selection of logistics equipment

Identification of suitable logistics equipment. Evaluation according to performance, integration effort and scalability.

Factory and hall structure in variants Derivation

Multiple variants of the hall and factory structure with structured comparison of variants. Decision preparation based on a list of criteria.

Detailed layout of the preferred variant

Development of the detailed layout for the selected preferred variant. Review of path relationships, storage areas and material flow quality.

Advantages of our solution

• Planning reliability: Sound dimensioning and clear planning assumptions reduce technical and operational risks.
• Increased efficiency: Optimized plant structure and material flows shorten travel times and stabilize throughput.
• Transparency: Variant comparison and detailed layout create a comprehensible basis for decision-making.
• Scalability: Pre-selected equipment and flexible space concepts support future expansion stages.
• Implementability: Early clarification of interfaces and reliable layouts speed up implementation.
   

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General planning for new combined casting and forging line at Bharat Forge Aluminiumtechnik GmbH & Co.KG

Overview

Location: Brand-Erbisdorf, Saxony, Germany
Project duration: 2012-2014 + follow-up projects to date
Production area: 6.800 sqm
Investment sum: €28 million + follow-up projects

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the general planning for the new construction of a combined casting and forging line. The aim was to design the systems, logistics, layout and technical building equipment (TGA) in an integrated manner, secure approvals and control the implementation with clear project management across all trades.

Project content

System and technology planning

Planning of the production systems and technological equipment. Definition of design parameters, media connections and functional areas for stable operation.

Space dimensioning

Determination of space requirements for production, logistics and technology. Focus on efficient plant structure and scalable expansion options.

Logistics planning

Conception of internal material flows, buffers and route relationships. Ensuring an efficient supply chain from raw materials to dispatch.

Layout design in 2D/3D

Development of a site-specific layout in 2D and 3D. Transparent visualization of installation areas, transfer points and media guides.

Interface clarification and management

Coordination of all trades with clear responsibilities. Early clarification of technical and structural dependencies reduces risks in execution and operation.

Approval planning (Federal Immission Control Act (BImSchG) and construction)

Development of approvable documents in accordance with BImSchG and building law. Accompanying the coordination with authorities until approval.

Construction and technical building equipment (TGA)

Planning service phases (LP) 1-8 according to the Fee Structure for Architects and Engineers (HOAI) Continuous planning of construction and TGA over LP 1-8 including project management and controlling of all construction trades. Structured preparation for execution with reliable documents.

Advantages of our solution

• Clear interfaces: Integrated management of plant, logistics, layout, MEP and construction minimizes technical risks.
• Approval security: Coordinated documents for BImSchG and construction accelerate procedures and increase planning security.
• Planning and implementation security: HOAI-compliant LP 1-8 with project management and controlling ensure deadlines and quality.
• Efficient plant structure: Space and logistics planning with 2D/3D layouts improves material flows and space utilization.
• Scalability: Designs and layouts can be adapted to volume fluctuations and future expansion stages.
   

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General planning for the new construction of the world's largest aluminum recycling plant at Novelis Europe / Novelis USA

Overview

Location: Nachterstedt, Saxony-Anhalt, Germany
Project duration: 2012-2015 + follow-up orders
Production area: approx. 60.000 sqm
Investment sum: over €200 million

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the general planning for the new construction of the world's largest aluminum recycling plant for Novelis Europe / Novelis USA. The aim of the project was to plan processes, plants and infrastructure holistically on a greenfield site, to ensure performance through simulation and to accompany the realization including commissioning on schedule.

Project content

General planning on a greenfield site

Integrated planning of production plants, ancillary processes, buildings and technical infrastructure. Early interface clarification for smooth plant construction.

Front End Engineering Design (FEED)

Concept planning Data acquisition and analysis as the basis for the basic engineering of production equipment, ancillary processes and buildings. Derivation of reliable design parameters and functional concepts.

Engineering (Procurement) Construction Management - E(P)CM

Detailed planning, tendering and supplier selection for production equipment. Logistics planning and simulation as well as detailed layout development in 2D/3D to ensure performance.

Implementation and construction coordination

Construction supervision and coordination with clear milestones and quality checks. Close control of execution to minimize risks and rework.

Supplier and start-up management

Coordination of suppliers across all trades. Structured start-up planning for media, systems and processes up to the stable start of operations.

Commissioning support

Tests and acceptances Support during commissioning with test and acceptance plans. Proof of the required performance and quality parameters for a reliable production start.

Advantages of our solution

• Comprehensive general planning: Integration of systems, logistics, buildings and technical infrastructure reduces interface risks.
• Planning reliability: FEED and E(P)CM with 2D/3D layouts and simulations create a reliable basis for design and decisions.
• On-time implementation: Structured construction coordination, supplier control and milestone management ensure that the project runs smoothly.
• Scalability and performance: Simulation-supported logistics and layout concepts enable high throughput and future expansions.
• Clear investment: Transparent tendering and selection processes increase cost control and quality within the scope of over €200 million.
   

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Relocation of plant and equipment for the assembly of the hood and doors of the Mercedes Benz Sprinter (T1N) at Mercedes-Benz Russia

Overview

Location: Mercedes-Benz Russia
Project duration: 5 months
Scope of relocation: 77 equipment items in 50 packages

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the relocation of plant and equipment for the assembly of the hood and doors of the Mercedes Benz Sprinter (T1N) for Mercedes-Benz Russia. The aim was to plan and carry out disassembly, packaging and preservation, transportation with customs clearance and handover in a complete and high-quality manner.

Project content

Inventory and documentation of the assembly systems

Analysis, recording and structured documentation of the relevant assembly systems at LÄPPLE Automotive Teublitz. Creation of a reliable data basis for packaging, transportation and recommissioning.

Packaging and preservation

Planning and implementation of protective and transportation packaging, including preservation measures. Ensuring transport protection, labelling and traceability.

Transport organization and customs clearance

Coordination of transports with compliant customs clearance and complete documentation. Management of deadlines, routes and service providers through to delivery.

Relocation in two batches

Execution of the relocation of 77 equipment items in 50 packages over two batches. Structured sequencing to minimize risks and throughput times.

Handover and export documentation

Quality-compliant handover at the destination location. Ensure complete export documentation as proof of compliance and acceptance.

Advantages of our solution

• Smooth relocation: End-to-end planning and coordinated execution reduce downtime and transportation risks.
• Documentation security: Complete, quality-compliant export documentation creates traceability and auditability.
• Customs compliance: Rule-compliant processing with clear documentation minimizes delays and liability risks.
• Deadline reliability: Structured batch planning and tight supplier control ensure milestones and handover dates.
• Transparency: Consolidated intake and transport data makes decisions easier and increases project control.
   

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Actual analysis and concept development in compliance with the AwSV at Daimler AG

Overview

Location: Esslingen a.N./Mettingen, Baden-Württemberg, Germany
Project duration: 4 months
Scope of installation: 3 cold chamber die casting machines

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out the as-is analysis and concept development for Daimler AG in compliance with the Ordinance on Installations for the Handling of Substances Hazardous to Water (AwSV). The aim was to reliably classify media and risks in accordance with AwSV, to develop compliant safety and separation concepts and to set up the documentation in a legally compliant and auditable manner.

Project content

Actual data analysis on cold chamber die casting machines

Collection and analysis of the relevant operating and process data on three cold chamber die casting machines, taking AwSV into account. Creation of a reliable data basis for derivations and measures.

Media analysis and hazard levels

Analysis of the media used and classification into hazard levels according to AwSV. Clear assignment for subsequent protection and handling concepts.

AwSV requirements and document management

Determination of regulatory requirements from the AwSV and establishment of structured document management. Ensuring traceability, completeness and up-to-dateness.

Safety concept in accordance with AwSV

Concept development for necessary safety equipment in conformity with AwSV. Definition of technical and organizational measures for safe operation.

Media separation

Concept development for the separation of water-polluting and non-water-polluting substances. Definition of storage, labelling and handling requirements to minimize risk.

Advantages of our solution

• Compliance safety: AwSV-compliant concepts and complete documentation reduce regulatory risks.
• Transparency: Structured media classification and clear derivations create traceability for technology and audits.
• Operational safety: Tailored safety and separation measures reduce the risk of failure and leaks.
• Decision basis: Concrete results per machine and area facilitate the prioritized implementation of measures.
   

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Relocation, camshaft production and cylinder head assembly at Daimler AG

Overview

Location: Yaroslavl, Russia
Project duration: 7 months
Scope of relocation: 14 machines and conveyor technology (camshaft), 20 assembly devices (cylinder head)
Transport weight: approx. 300 tons (camshaft), approx. 100 tons (cylinder head)

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the relocation of camshaft production and cylinder head assembly from Stuttgart-Untertürkheim to Yaroslavl for Daimler AG. The aim was to smoothly plan and execute disassembly, packaging, interim storage, transportation with customs clearance, assembly and commissioning.

Project content

Relocation planning and project management

Structured planning of the end-to-end process with milestones, resources and risks. Ensuring a smooth transition from the old to the new location.

Disassembly and packaging

Proper disassembly of the systems and conveyor technology. Protective and transport packaging in accordance with technical and logistical requirements.

Interim storage and customs clearance

Organization of interim storage including inventory and status management. Customs clearance in accordance with regulations with complete documentation of the system parts.

Heavy transport and logistics

Coordination of transports for total weights of approx. 300 tons (camshaft) and approx. 100 tons (cylinder head). Planning of routes, lifting and securing measures up to delivery.

Assembly and commissioning (IBN)

Re-assembly of the machines and setting up the conveyor technology. Functional checks, test runs and acceptance preparation up to the start of production.

Interface and supplier coordination

Coordination with the trades, service providers and authorities involved. Clarification of technical interfaces and on-site implementation support.

Advantages of our solution

• Smooth relocation: End-to-end planning and coordinated implementation minimize downtime and risks.
• Deadline reliability: Clear milestones and structured project management secure the time frame.
• Compliance and customs clarity: Compliant documentation and processing reduce delays and liability risks.
• Quality assurance: Defined test and acceptance steps ensure function and performance after installation.
• Transparency: Consolidated reports and clear responsibilities increase traceability and decision-making capability.
   

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New SKD line (semi-knock-down) construction at Magna Steyr Fahrzeugtechnik AG & Co. KG

Overview

Location: Graz, Styria, Austria
Scope of installation: SKD processing line with 6 workstations for painted car bodies
Equipment: Working platform, infrastructure, cavity preservation, conveyor technology (roller conveyors, shears, lifters, 4-point transfer unit)

HÖRMANN Rawema Engineering & Consulting GmbH has successfully implemented the new construction of a semi-knock-down (SKD)- line für Magna Steyr Fahrzeugtechnik AG & Co. KG was implemented. The aim was to plan, procure and implement a high-performance processing line with reliable functionality and to professionally prepare for commissioning and acceptance.

Project content

Processing line with six stations

Design of the work stations for cavity preservation, tooling disassembly, packaging and transfer to transport racks. Clear process sequences and transfer points for stable workflows.

System scope and conveyor technology

Integration of work platform, infrastructure and cavity preservation. Conveyor technology with roller conveyors, scissors, lifters and 4-point-transformers for efficient handling.

Concept and detailed planning

Development of the concept and detailed planning with layout in 2D/3D. Definition of interfaces, media connections and security requirements.

Tendering and award support

Preparation of tender documents, technical clarifications and tender evaluation. Structured awarding of contracts to ensure quality, deadlines and costs.

Site supervision and coordination

Coordination of implementation on site with a clear trade interface. 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 including verification of performance and safety parameters.

Advantages of our solution

• Functional reliability: Consistent concept and detailed planning with clear interfaces ensures stable processes in the SKD line.
• On-time implementation: Structured tendering, awarding and construction site coordination reduce delays and rework.
• Efficient handling: Integrated conveyor technology (roller conveyors, scissors, lifters, 4--point--transformers) reduces cycle times and improves ergonomics.
• Transparency in procurement: Precise documentation and quotation evaluation create comparability and cost control.
• Maturity of implementation: IBN support and acceptance preparation accelerate the start of production and ensure quality.
   

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Logistics concept for an aluminum rolling mill at Novelis Deutschland GmbH

Overview

Location: Nachterstedt, Saxony-Anhalt, Germany
Project duration: 5 months
Focus: Dimensioning, process optimization, layout, simulation

HÖRMANN Rawema Engineering & Consulting GmbH successfully developed a logistics concept for an aluminium rolling mill at Novelis Deutschland GmbH. The aim was to dimension the automatic logistics system and the track infrastructure in a resilient manner, to stabilize material flows and to design shipping and scrap circulation efficiently.

Project content

Data collection Production program and logistics system

Systematic collection of the production program and the framework conditions of the automatic logistics system. Consolidated data as a basis for design and simulation

Dimensioning and simulation of the logistics system

Calculation and simulation of capacities, throughputs and buffer areas. Evaluation of expansion concepts including track systems to ensure efficiency.

Rough layout

Development of a rough layout with functional, logistics and technical areas. Clear route relationships and delivery logics for a stable material flow.

Dispatch: Dimensioning and concept planning Design of dispatch processes and areas. Development of delivery and loading concepts to ensure predictable pick-up and delivery windows.

Optimization of the scrap cycle Analysis of the scrap cycle and derivation of measures to reduce cycle times and handling costs. Integration into the overall layout and logistics processes.

Budgeting and schedule Creation of a reliable budget and schedule. Transparent basis for decisions and step-by-step implementation.

Advantages of our solution

• Planning reliability: Well-founded dimensioning and simulation create reliable capacity and throughput forecasts.
• Increased efficiency: Optimized logistics and shipping processes reduce travel times, waiting times and handling costs.
• Transparency: Rough layout and clear delivery logic make interfaces and areas visible at an early stage.
• Scalability: Expansion concepts including track systems enable a gradual increase in performance.
• Decision clarity: Budgeting and scheduling provide a reliable basis for investment and implementation decisions.
   

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