Infrastructure planning final assembly BMW G30 & G/J29 at MAGNA STEYR Fahrzeugtechnik

Overview

Location: Graz, Styria, Austria
Project duration: 12 months
Total volume: approx. 4 million €

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the infrastructure planning for the final assembly of the BMW G30 and G/J29 series for MAGNA STEYR Fahrzeugtechnik. The project aimed to plan secondary and media steel construction as well as process and plant media, prepare relocations and new buildings and ensure implementation through structured tendering and coordinated supplier monitoring.

Project content

Infrastructure planning for secondary and media steel construction

Planning of secondary and media steel construction as well as process and plant media (compressed air, electrics, special media), lighting, extraction systems and social areas.

Conversion and new construction of infrastructure in assembly areas

Planning responsibility for partial conversion and new construction of infrastructure for assembly lines, pre-assembly, offline areas and plant and line supply.

Plant relocations and new builds

Preparation and coordination of plant relocations and new builds with clear interfaces and defined schedules.

Tendering, technical clarifications and tender review

Prepare tender documents, carry out technical clarifications and structured tender review. Procurement and processing of new orders.

Supplier coordination and monitoring

Supplier management and close coordination with peripheral departments during the realization phase. Ensuring quality, deadlines and interfaces.

Advantages of our solution

• Clear interfaces: Integrated planning of media steel construction, process and plant media, lighting and extraction systems reduces technical risks.
• On-time implementation: Structured tendering, tender review and supplier monitoring stabilize implementation and start dates.
• Investment transparency: Coordinated procurement and clear responsibilities ensure budget adherence in the total volume of approx. 4 million.
• Operational readiness: Planned conversions and new buildings as well as coordinated relocations enable the assembly areas to be commissioned quickly.
   

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Hook-up coordination / 3D collision check / as-built documentation at Robert Bosch Semiconductor Manufacturing

Overview

Location: Dresden, Saxony, Germany
Project duration: Oct. 2019 to July 2020
Total construction area: approx. 100.000 sqm
Investment sum (total): around €1 billion

HÖRMANN Rawema Engineering & Consulting GmbH successfully supported the hook-up coordination, 3D collision check and as-built documentation for Robert Bosch Semiconductor Manufacturing. The aim was to ensure collision-free integration of the plant technology in the semiconductor and cleanroom environment, coordinate trades and interfaces and document progress transparently.

Project content

3D collision check execution planning

Check the execution planning models for collisions and interface conflicts. Early rectification to ensure smooth installation.

Construction monitoring

Continuous monitoring of execution on site. Comparison with planning statuses and ensuring high-quality implementation.

Trade and interface coordination (hook-up)

Coordination of all trades involved and their media connections in the hook-up process. Clarification of technical interfaces between the system, layout and technical infrastructure.

Progress monitoring and documentation

End-to-end monitoring of milestones with traceable documentation. Transparency regarding construction progress, acceptances and open points.

3D collision check

As-built models Validation of as-built models using 3D collision check. Comparison of actual status versus planning to ensure operational safety.

Advantages of our solution

• Collision-free: 3D checks in the execution and as-built phase minimize rework and downtime.
• Interface reliability: Structured hook-up and trade coordination clarifies media, connections and responsibilities.
• Deadline reliability: Continuous progress monitoring and clear documentation stabilize processes and milestones.
• Cleanroom compliance: Quality assurance and interface management take into account the requirements of the semiconductor and cleanroom environment.
• Transparency: Consistent as-built documents create a reliable basis for operation and subsequent changes.
   

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General planning of a combined casting and forging line in existing halls at Bharat Forge Aluminiumtechnik GmbH and forging line in existing halls at Bharat Forge Aluminiumtechnik GmbH

Overview

Location: Brand-Erbisdorf, Saxony, Germany
Project duration: 2017 - 2021
Production area: 14.000 sqm
Investment sum: over €23 million

HÖRMANN Rawema Engineering & Consulting GmbH has successfully implemented the general planning of a combined casting and forging line in several existing halls for Bharat Forge Aluminiumtechnik GmbH. The aim was to plan processes and infrastructure in an integrated manner, secure approvals and implement the project on schedule over three construction phases.

Project content

Production and logistics planning

Integrated planning of production processes and material flows. Focus on stable processes, clear transfer points and efficient supply chains.

Layout design in 2D/3D

Creation of a site-specific layout in 2D and 3D. Transparent visualization of set-up areas, path relationships and media connections.

Conversion measures in existing halls (3 construction phases)

Planning and implementation of conversion measures in several halls. Skilful construction phase planning to safeguard operations and minimize downtime.

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 execution trades. Structured preparation for execution with reliable documentation.

3D laser scanning for revision documentation

Recording of the existing building using 3D laser scanning. Provision of audit-proof documentation as a basis for operation and further measures.

Advantages of our solution

• Interface clarity: Integrated management of all trades reduces technical risks and speeds up implementation.
• Approval security: Coordinated documents for BImSchG and construction facilitate 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: 2D/3D layouts and production/logistics planning improve material flows and space utilization.
• Transparent documentation: 3D laser scans and revision documents create a reliable basis for operation and further planning.
   

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General planning for restructuring / new construction / relocation of production at Heraeus Site Operations GmbH & Co KG

Overview

Location: Hanau/Kleinostheim, Hesse/Bavaria, Germany
Project duration: since 2017
Production/laboratory area: approx. 12.000 sqm Investment sum: over €80 million

HÖRMANN Rawema Engineering & Consulting GmbH has been supporting the general planning for the restructuring, new construction and relocation of production for Heraeus Site Operations GmbH & Co KG since 2017. The project aims to integrate the planning of facilities, logistics, technical building equipment (TBE) and construction, secure approvals and implement relocations smoothly.

Project content

General planning of facilities, logistics, TBE and construction

Integrated planning of all relevant trades. Interfaces are clarified at an early stage to ensure efficient and safe operation.

Determination of basic conditions, preliminary and design planning

Systematic survey of basic conditions and preparation of preliminary and design planning. Reliable basis for design, layout and investment decisions.

Involvement in approval planning (BImSchG + construction)

Support in approval planning in accordance with the Federal Immission Control Act (BImSchG) and construction law. Preparation of documents and support in coordination with authorities.

Execution planning

Detailed elaboration of the technical and structural execution. Transparent planning steps to ensure deadlines and quality.

Tendering and awarding

Preparation of tender documents and structured awarding of contracts for all trades. Comparable offers and clear service descriptions ensure cost-effectiveness.

Supplier and project monitoring

Coordination of suppliers and monitoring of execution on site. Quality assurance and risk minimization during implementation.

Relocation planning and management

Planning and management of the production relocation. Detailed relocation logistics, ramp-up concepts and safeguarding of production capability.

Advantages of our solution

• Comprehensive general planning: Integration of plant, logistics, technical building equipment (TGA) and construction reduces interface risks.
• Approval security: Involvement in BImSchG and building approvals speeds up procedures and increases planning security.
• On-time implementation: Consistent implementation planning, tendering and awarding create clear milestones and reliable processes.
• Quality and risk: Supplier and project monitoring ensures execution quality and minimizes project risks.
• Smooth relocation: Structured relocation planning and management ensure continuity and rapid stabilization of production.
   

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Concept planning for the coilStorage and loading in the rolling mill at ESF Elbe-Stahlwerke Feralpi GmbH

Overview

Location: Riesa, Saxony, Germany
Project duration: 2 months
Production/logistics area: 14.000 square meters

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the concept planning for coil storage and loading in the rolling mill for ESF Elbe-Stahlwerke Feralpi GmbH. The aim was to dimension storage, transport and ancillary areas as well as means of transport in a resilient manner, to structure material flows for storage, picking and loading and to determine a preferred variant based on a well-founded comparison of variants.

Project content

Data collection and framework analysis

Collection of relevant fundamentals and analysis of existing logistics flows. Clean data as a basis for dimensioning, layout and evaluation.

Space and capacity dimensioning

Dimensioning of storage, transport and ancillary areas, including parking space and buffer concepts. Derivation of capacities for a stable material flow.

Means of transport and fleet requirements

Determination of the types of means of transport and the required number. Design of areas of use and capacity utilization to ensure efficient operation.

Storage, picking and loading concepts

Development of process concepts for storage, picking and loading. Clear interfaces, transfer points and delivery logic for smooth processes.

Creating and evaluating layout variants (2D/3D)

Creating and evaluating various layout variants in two dimensions (2D) and three dimensions (3D). Examination of path relationships, parking spaces and material flow quality.

Variant comparison and preferred variant

Structured comparison of layout variants based on a catalog of criteria. Selection of the preferred variant with a reasoned decision recommendation.

Structural requirements

Evaluation of the structural requirements and interfaces. Derivation of necessary measures for implementation in existing buildings.

Advantages of our solution

• Planning reliability: Sound dimensioning and clear comparison of variants create a reliable basis for decision-making.
• Efficient material flows: Sophisticated concepts for storage, picking and loading reduce handling times and stabilize throughput.
• Transparency: 2D planning and 3D visualization make route relationships, areas and interfaces visible at an early stage.
• Scalability: Designs and layouts can be flexibly adapted to quantity and expansion stages.
• Implementability: Early clarification of construction requirements reduces risks and speeds up implementation.
   

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Simulation of shunting processes at Novelis Deutschland GmbH

Overview

Location: Nachterstedt, Saxony-Anhalt, Germany
Project duration: 3 months
Focus: Simulation, rail logistics, shunting

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out the simulation of shunting processes for Novelis Deutschland GmbH. The aim was to realistically map shunting processes, dimension capacities and vehicle requirements and derive optimal sequences and travel times for a stable interface supply between logistics and production.

Project content

Simulation model of the shunting processes

Mapping of the shunting processes in a simulation model, taking into account the plant logistics and processes. Representation of routes, parking and transfer points.

Shunting logics under boundary conditions

Development of suitable shunting logics according to operational framework conditions. Ensuring robust processes despite restrictions and bottlenecks.

Optimal wagon sequences (inbound trains)

Determining optimal sequences for inbound trains. Reduction of transfer times and stabilization of the supply to the production areas.

Track system expansion requirements

Determination of the necessary expansion of the track systems in terms of number and length. Technical and economic assessment to safeguard investments.

Shunting vehicle numbers and utilization

Determination of the required number and utilization of shunting vehicles. Dimensioning for high-performance, cost-efficient operation.

Arrival and departure times

Determination of optimum arrival and departure times in the work cycle. Smoothing out peaks and ensuring plannable logistics windows.

Advantages of our solution

• Decision reliability: Realistic simulations and clear evaluations create a reliable basis for measures.
• Infrastructure clarity: Determined expansion requirements for track systems make investments comparable and plannable.
• Resource efficiency: Dimensioned number of vehicles and capacity utilization reduce operating costs and increase availability.
• Time stability: Optimized arrival and departure times smooth out peaks and ensure interface supply.
• Process quality: Optimal wagon sequences shorten turnaround times and stabilize the material flow to production.
   

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3D laser scanning and 3D modeling at Inolares GmbH & Co. KG

Overview

Location: Berlin, Germany
Project duration: 2 months
Special features: Smoke extraction duct, confined space, scan over several floors

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented 3D laser scanning and 3D modeling for Inolares GmbH & Co. KG. The aim was to precisely record the existing building, prepare the scan data in a reliable manner and provide an overall model as a basis for further planning of the technical building equipment (TBE).

Project content

As-built survey using 3D laser scanning

High-resolution recording of buildings and infrastructure. Documentation of critical areas such as smoke extraction ducts and multi-storey zones.

Capture methodology: terrestrial scanners and handheld

Combined use of terrestrial laser scanners and handheld devices. Ensuring complete measurement coverage despite limited space.

Scan data preparation

Registration, cleansing and structuring of the point clouds. Quality assurance and coordinate reference for consistent further use.

3D computer-aided design (CAD)

Modeling of the trades 3D modeling of buildings, ventilation, piping, electrical and technical infrastructure. Consistent level of detail for cross-trade planning.

Overall model and TGA basis

Creation of a consistent overall model as the basis for TGA planning. Clear visualization of installation areas, media routes and interfaces.

2D comparison

Check the 3D models against existing 2D documents. Ensure dimensional accuracy and completeness for downstream steps.

Advantages of our solution

• Precise data basis: Combined scanning provides complete and detailed as-built information.
• Planning transparency: The overall model provides a clear view of trades, media routing and interfaces.
• Integration capability: TGA-compliant model structure facilitates further planning and reduces rework.
• Efficiency in existing buildings: Methodology copes with cramped conditions and multi-storey areas without disrupting operations.
• Quality assurance: Structured data preparation and 2D comparison increase dimensional accuracy and reliability.
   

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Study for production expansion & consulting for organizational development at GS Bavaria GmbH

Overview

Location: Nuremberg, Bavaria, Germany
Project duration: 3 months
Production area (greenfield): 2.000 sqm

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented a study on production expansion and organizational development consulting for GS Bavaria GmbH. The aim was to expand the recycling process from hard metal scrap to tungsten nanopowder in a structured manner, to visualize layouts and models and to create a reliable basis for costs, deadlines and organization.

Project contents

Recycling process and target image

Definition of the process framework for the recycling of hard metal scrap to tungsten nanopowder. Derivation of a clear target image as the basis for layout, capacities and organization.

Data collection and structuring (workshops)

Collection and structuring of all relevant data in moderated workshops. Creation of a consistent data basis for planning and decision-making.

2D layouts for pilot production and greenfield

Development of a 2D layout for pilot production in the existing building and for the greenfield. Clear layout of functional, logistics and technical areas.

3D models and renderings

Creation of 3D models and rendering of 3D views. Early visualization for the evaluation of installation areas, path relationships and interfaces.

Cost framework and schedule (greenfield)

Determination of a cost framework and schedule for the greenfield. Transparent basis for budgeting and implementation steps.

Roadmap for organizational development

Development of a structured checklist/roadmap for further corporate and organizational development. Prioritized measures for roles, processes and communication.

Joint workshop

Conducting a workshop to discuss the results together. Coordination of the next steps and definition of responsibilities.

Advantages of our solution

• Holistic approach: Combines process, layout, visualization, costs and organization into a consistent basis for decision-making.
• Transparency through visualization: 2D layouts and 3D models with renderings make areas, paths and interfaces visible at an early stage.
• Planning security: Cost framework and schedule for the greenfield reduce investment and implementation risks.
• Structured development: The roadmap supports predictable organizational development with clear priorities.
• Accelerated decision-making: Workshops, consolidated data and clear documentation shorten coordination processes and increase commitment.
   

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3D laser scanning and 3D modeling / 2D alignment at Flender Industriegetriebe GmbH

Overview

Location: Penig, Saxony, Germany
Project duration: 4 months
Production area: 14.000 sqm

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented 3D laser scanning, 3D modeling and 2D alignment for Flender Industriegetriebe GmbH. The aim was to precisely record the existing situation, create a reliable overall 3D model and ensure the data interfaces for further planning and integration.

Project content

As-built survey using 3D laser scanning

High-resolution recording of the existing plant and building condition. Basis for precise modeling and reliable planning.

Scan data preparation

Registration, cleansing and structuring of the scan data. Quality assurance and coordinate reference for consistent further use.

3D computer-aided design (CAD)

Modeling of the trades 3D modeling of production facilities, cranes, buildings and technical infrastructure. Uniform level of detail for a clear, cross-trade view.

Overall model and hall models

Creation of a consistent overall model and individual hall models. Structured visualization for planning, coordination and documentation.

Unification of machine models

Derivation of individual machine models from the overall model. Targeted provision for specific planning and coordination tasks.

2D drawing comparison

Comparison of the 3D model with as-built drawings in 2D. Ensuring consistency, dimensional accuracy and completeness.

File transfer and Siemens NX compatibility

Ensuring the compatibility of models with Siemens NX. High-performance export and seamless data exchange with downstream systems.

Advantages of our solution

• Precision: High-resolution laser scans and structured data preparation increase the accuracy of as-built models.
• Planning transparency: 3D overall and hall models create a clear basis for decision-making for all trades.
• Integration capability: Siemens NX-compatible models facilitate collaboration and further processing.
• Consistency: 2D alignment ensures dimensional accuracy and reduces rework in planning and execution.
• Reusability: Isolated machine models accelerate variant creation and change planning.
   

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General planning to support layout and fire protection at Erfurter Teigwaren GmbH

Overview

Location: Erfurt, Thuringia, Germany
Project duration: 6 months
Production area: approx. 16.000 sqm

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the general planning to support the layout and fire protection for Erfurter Teigwaren GmbH. The aim was to safely and efficiently align the large-scale production of 100,000 tons per year, update plans and prepare structural and fire protection measures for approval.

Project content

Process requirements for large-scale production

Recording the specific requirements of large-scale production of pasta (100,000 t/year). Translation of the process requirements into clear layout and infrastructure specifications.

Data collection, analysis and list of measures

Systematic collection of relevant data and analysis of the current situation. Derivation of a prioritized list of measures as a basis for implementation and monitoring.

Updating floor plans and layouts (2D)

Updating the floor plans and 2D layouts of the entire building. Clear visualization of functional areas, route relationships and area allocations.

Escape and rescue plans, fire department plans

Revision of the escape and rescue plans and fire department plans. Ensuring completeness, legibility and standard-compliant presentation.

Structural and fire protection measures

Planning, tendering and implementation support for selected structural and fire protection measures. Interface coordination to minimize execution risks.

Supply air and exhaust air concepts

Revision of supply air and exhaust air concepts in the production environment. Improvement of air quality, energy efficiency and operational stability.

Authority consultations

Support with consultations with the relevant authorities. Preparation of documents and monitoring of communication through to approval.

Advantages of our solution

• Safety and compliance: Updated plans and coordinated measures meet fire safety requirements and increase operational safety.
• Transparency: Consistent 2D layouts and structured action lists create a clear basis for decision-making and implementation.
• Efficiency in the food environment: Process and layout optimizations support stable processes and high quality in large-scale production.
• Reliable implementation: Planning, tendering and implementation support reduce time, cost and interface risks.
• Clarity with authorities: Professional support in coordinating with authorities speeds up approvals and reduces rework.
   

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