General planning for new production hall at YINLUN SETRAB POLAND Sp. z o.o.

Overview

Location: Karlino, Poland
Project duration: 2020-2023
Production area: 10.000 sqm
Investment sum: €11 million

HÖRMANN Rawema Engineering & Consulting GmbH has successfully implemented the general planning for the construction of a new production hall for YINLUN SETRAB POLAND Sp. z o.o.. The aim was to design space-efficient processes, provide documents ready for approval and enable smooth, punctual implementation.

Project content

Space dimensioning

Determination of space requirements for production, logistics and technology. Focus on efficient plant structure and future-proof scaling.

Logistics planning

Conception of internal material flows, route relationships and buffer areas. Ensuring stable processes from goods receipt to dispatch.

Layout design in 2D/3D

Creation of a site-specific layout in two dimensions (2D) and three dimensions (3D). Transparent visualization of installation areas, media connections and functional areas.

Interface clarification and management

Coordination of all trades with clear interfaces. Early clarification of technical and structural dependencies to minimize risk.

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

Drafting of the necessary approval documents for BImSchG and construction. Preparation of the application process and coordination with the relevant authorities.

Construction and technical building equipment (TGA)

Planning service phases (LP) 1-7 according to the Fee Structure for Architects and Engineers (HOAI) Continuous planning of construction and TGA over the LP 1-7 incl. project management. Structured preparation for execution with reliable documents.

Advantages of our solution

• Clear interfaces: Integrated management of all trades reduces technical risks and speeds up implementation.
• Planning reliability: Approvable documents (BImSchG and construction) and HOAI-compliant LP 1-7 ensure reliable decisions.
• Efficient plant structure: Space and logistics planning optimizes material flows and supports efficient production.
• Transparency: 2D/3D layouts create a clear view of installation areas, media and functional areas.
• Investment security: Stringent general planning supports the plannable realization within the scope of €11 million.
   

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Conception of an automatic coil & scrap handling system at Novelis Deutschland GmbH - Ohle site

Overview

Location: Ohle (Plettenberg), North Rhine-Westphalia, Germany
Project duration: May 2023 - January 2024
Production area: approx. 8.000 sqm
Scope of planning: approx. 150 T€

HÖRMANN Rawema Engineering & Consulting GmbH has successfully implemented the conceptual design of an automatic coil & scrap handling system for Novelis Deutschland GmbH - Ohle site. The project aimed to automate material flows, design the new system technology functionally and safely and verify the performance requirements using simulation.

Project content

Automatic conveyor systems for coils and scrap

Conception of automatic conveyor systems for coils, residual windings and empty coils as well as scrap containers. Integration of two coil shears into the overall system with defined transfer points and interfaces.

3D concept planning of the system technology

Development of 3D concept planning including conceptual modeling of the new technology. Visualization of installation areas, path relationships and media connections to ensure integration.

Function and performance simulation

Simulation of the system technology to verify the required functionalities and performance parameters. Evaluation of throughput, availability and bottlenecks as a basis for the design.

Overall safety concept

Conception of an overarching safety concept for systems, handovers and operating processes. Consideration of normative requirements and operational safety measures.

Designing construction measures

Determination of the necessary construction measures for foundations, supporting structure and infrastructure. Clarification of interfaces between technology, construction and operation.

Functional tender

Development of functional tender documents for plant technology and construction measures. Precise service descriptions for structured bid solicitation and evaluation

Advantages of our solution

• Verified performance: Simulations confirm functionality and performance parameters before implementation.
• Interface clarity: 3D concept planning makes transfer points, installation areas and media connections transparent.
• Operational safety: A holistic safety concept increases protection and availability during operation.
• Readiness for implementation: Functional tenders accelerate procurement and ensure comparability of offers.
• Efficient material flows: Sophisticated conveyor concepts for coils and scrap stabilize throughput and reduce handling costs.
   

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Planning support for casting volume expansion incl. new exhaust air system at Constellium Singen

Overview

Location: Singen, Baden-Württemberg, Germany
Project duration: 2022-2023
Investment amount: 12 m. €

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the planning support for the expansion of the casting volume including a new exhaust air system for Constellium Singen. The project aimed to clarify technical and structural interfaces, prepare for implementation and secure budget and supplier decisions.

Project content

Specific specifications for melting furnace and exhaust air system

Creation of precise specifications as a basis for inquiries to potential suppliers. Clear service descriptions and interfaces ensure comparability and quality.

Layout and infrastructure planning

Development of a site-specific layout and technical infrastructure. Consideration of media connections, pathways and set-up areas for smooth operation.

Preliminary planning of the hall extension

Preliminary planning of the structural extension with definition of the structural requirements. Coordination of areas, supporting structure and approval requirements.

Budget planning

Resilient budget planning within a framework of €12 million. Transparent cost breakdown to safeguard investment decisions.

Supplier management

Structured inquiry and quotation processes. Coordination of suppliers, clarification of interfaces and evaluation of offers.

Risk management

Identification of technical, scheduling and financial risks. Derivation of measures to minimize and safeguard implementation.

Advantages of our solution

• Interface clarity: Integrated layout, infrastructure and preliminary construction planning clarifies media, areas and processes.
• Investment security: Transparent budget planning and precise specifications make costs and scope of services comparable.
• Implementation capability: Clearly prepared tenders and professional supplier management accelerate procurement and implementation.
• Risk transparency: Early risk analysis with specific measures reduces technical and time-related uncertainties.
• Quality assurance: Coordinated requirements ensure the functionality of the melting furnace and exhaust air system.
   

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Concept planning for the use of an AGV in the assembly area at Clarios GmbH & Co.KG

Overview

Overview Location: Zwickau, Saxony, Germany
Project duration: 4 months
Production/logistics area: approx. 10.000 sqm
Investment sum: over €3 million

HÖRMANN Rawema Engineering & Consulting GmbH successfully implemented the concept planning for the use of an automated guided vehicle system (AGV) in the assembly area for Clarios GmbH & Co.KG. The project aimed to automate internal logistics, stabilize material flows and sustainably increase efficiency.

Project content

Data collection and framework analysis

Collection of the relevant basics and detailed analysis of the logistics flows. Clean data as a basis for further design and evaluation.

Material flow visualization with visTABLE

Visualization of material flow relationships using visTABLE in 2D/3D. Transparent representation of path relationships, transfer points and buffer areas.

Implementation variants

Development of several implementation variants for AGV use. Evaluation according to performance, integration effort, scalability and operational reliability.

Dimensioning the AGV

Determination of the number, areas of application and utilization of the automated guided vehicle system (AGV). Derivation of the required vehicle configurations and routes for stable operation.

Supplier coordination

Coordination with potential suppliers on technical solutions, interfaces and service concepts. Targeted preparation for bid and selection processes.

Rough cost estimate for systems and logistics

Rough cost estimate for AGVs, infrastructure and logistics processes. Link to milestones for reliable decision-making and scheduling.

Advantages of our solution

• Increased efficiency: Automated material flows reduce travel times and stabilize throughput in assembly.
• Transparency: visTABLE visualizations provide clarity about routes, transfers and buffer concepts.
• Planning reliability: Variant comparison and AGV dimensioning minimize technical and operational risks.
• Scalability: Modular system structure enables gradual expansion and adaptation to production volumes.
• Investment clarity: Rough cost estimate tailored to an investment framework of over €3 million supports well-founded decisions.
   

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Building feasibility study for test benches at AVL Deutschland GmbH

Overview

Location: Bavaria, Germany
Project duration: 6 weeks
Constructed area: approx. 250 sqm, 3 floors

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out a feasibility study for a building with test benches for fuel cells for AVL Deutschland GmbH. The aim was to evaluate a structurally and functionally viable solution in solid construction as an alternative to the container solution, to confirm the feasibility and to provide a reliable cost framework.

Project content

Requirements for test benches for fuel cells

Evaluation and structuring of the technical and spatial requirements for the test benches. Definition of the interfaces to building and infrastructure planning.

Layout and model development in solid construction

Development of a layout design and model in solid construction as an alternative to the container solution. Creation of floor plans, sections, elevations and a 3D model to support decision-making.

Solution coordination and decision

Coordination of the structural and functional solution based on the layout. Moderation of the decision with the relevant stakeholders in the greenfield context.

Preliminary structural design and feasibility check

Preliminary structural design and technical feasibility check. Evaluation of the execution in solid construction or reinforced concrete design.

Cost framework according to DIN 276

Development of a cost framework according to DIN 276 (standard of the German Institute for Standardization). Transparent cost breakdown as a basis for further project phases.

Results report and documentation

Production of the results report including object description and feasibility statement. For reasons of confidentiality without illustrations; provision of all relevant content in text form.

Advantages of our solution

• Decision certainty: Clear feasibility statement and reliable documentation create a sound basis for implementation.
• Cost transparency: The cost framework in accordance with DIN 276 enables structured budgeting and reduces financial risks.
• Construction reliability: Structural pre-dimensioning and variant evaluation ensure technical feasibility.
• Comparability of alternatives: Layout and model development makes the differences between solid construction and container solutions visible.
• Planning basis: Complete documentation with floor plans, sections, elevations and 3D model supports the next steps of general planning.
   

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Feasibility analysis and material flow simulation at Schwermetall-Halbzeugwerk GmbH & Co. KG

Overview

Location: Stolberg, Germany
Simulation environment: 3D environment
Database: Real-time production data

HÖRMANN Rawema Engineering & Consulting GmbH has successfully carried out a feasibility analysis and material flow simulation for Schwermetall-Halbzeugwerk GmbH & Co. KG. The project aimed to conceptually evaluate an automated coil warehouse, optimize material flows and simulate the effects of changing processes in a resilient manner.

Project content

Warehouse concept for automated coil warehouse

Creation of a practical warehouse concept with clear functional areas, transfer points and interfaces. The basis for safe and scalable coil logistics.

Update, analyze and expand material flow

Update the existing material flow, analyze bottlenecks and add automated processes. Targeted dimensioning of throughputs and buffer areas.

Layout variants (2D/3D)

Development of layout variants in 2D and 3D. Evaluation of path relationships, storage areas and installation conditions in the context of the hall.

Simulation of capacity, utilization and intensities

Simulation of storage capacities, utilization and handling intensities in a 3D environment. Integration of real-time production data for realistic results.

Traffic simulation and trajectories

Simulation of the traffic situation with trajectories for trucks. Safeguarding of routes, turning areas and delivery points.

Feasibility analysis of changed material flows

Evaluation of the feasibility of process changes and their impact on performance and stability. Derivation of recommendations for implementation.

Advantages of our solution

• Decision reliability: 3D simulations with real-time data create a reliable basis for variant selection and design.
• Planning reliability: Precise dimensioning of capacities and buffer areas reduces technical and operational risks.
• Increased efficiency: Optimized material flows stabilize throughput and shorten distances.
• Traffic safety: Tracking curve analyses safeguard deliveries, maneuvering areas and operations.
   

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Concept planning of an automatic high-bay racking system for coils at Schwermetall-Halbzeugwerk GmbH & Co. KG

Overview

Location: Stolberg, Germany
Storage area: approx. 1.800 sqm
Storage capacity: 800 coils
Maximum coil weight: 25 tons

HÖRMANN Rawema Engineering & Consulting GmbH successfully completed the concept planning for an automated high-bay racking system for coil storage for Schwermetall-Halbzeugwerk GmbH & Co. KG. The aim was to develop a resilient storage concept, optimize material flows and reliably simulate capacities and traffic situations.

Project content

Storage concept for automated coil storage

Creation of a practical storage concept with clear functional areas, transfer points and interfaces. The basis for efficient, safe and scalable coil logistics.

Update, analyze and expand material flow

Update the existing material flow, analyze bottlenecks and add automated processes. Targeted dimensioning of throughputs and buffer areas.

Optimization potential

Systematic development of optimization potential along warehouse, transport and transfer. Prioritized measures to increase efficiency and availability.

Layout variants (2D/3D)

Creation of layout variants in two dimensions (2D) and three dimensions (3D). Evaluation of route relationships, storage areas and set-up conditions in the context of the hall.

Simulation of storage capacity, capacity utilization, intensities

Simulation of storage capacities and capacity utilization including picking and handling intensities. Basis for decision-making for the dimensioning and performance of the system.

Traffic simulation and trajectories

Simulation of the traffic situation with trajectories for trucks. Safeguarding of routes, turning areas and delivery points.

Specifications and supplier management

Drafting of specifications with clear descriptions of services and interfaces. Requesting and evaluating offers for the structured selection of suitable suppliers.

Advantages of our solution

• Planning reliability: Simulated capacities and reliable layouts reduce risks in design and operation.
• Efficient material flows: Updated and expanded flow concepts shorten routes and stabilize throughput.
• Transparency: Variants and simulations create clear comparability and well-founded decisions.
• Traffic safety: Tractrix curve and traffic simulations ensure delivery and maneuvering areas.
• Supplier clarity: Precise specifications and structured evaluation strengthen quality and cost control.
   

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Variant comparison of neutralization systems at Novelis Deutschland GmbH - Nachterstedt plant

Overview

Location: Nachterstedt, Germany
Project duration: Q4/2023 - Q2/2024
Investment sum: over €2.5 million. €

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out a comparison of variants for neutralization systems at the Nachterstedt plant. The aim was to identify the best technical and economic solution, clarify interfaces at an early stage and create a reliable basis for investment decisions.

Project content

Data collection

Systematic collection of relevant plant data, boundary conditions and requirements. Consolidation of the information as a basis for the assessment.

Determination of basic principles

Determination of technical and regulatory principles for neutralization systems. Definition of design parameters and interfaces to the technical infrastructure.

Supplier research and enquiries

Identification of suitable suppliers and preparation of clear inquiry documents. Comparison of offers according to scope of services, quality and deadlines.

Layout planning

Development of a site-specific layout with installation areas, media connections and logistical routes. Consideration of structural requirements and interfaces to production and operations.

Variant comparison

Evaluation of several solution variants based on a catalog of criteria. Comparison of technical performance, cost-effectiveness, risks and scalability.

Budget calculation

Reliable cost estimate for investment and operation. Transparent comparison with the investment framework of over €2.5 million.

Scheduling

Creation of a realistic schedule with milestones for procurement, installation and commissioning. The basis for plannable implementation.

Advantages of our solution

• Founded basis for decision-making: Structured comparison of variants creates transparency and reduces wrong decisions.
• Cost certainty: Reliable budget calculation and investment comparison increase planning certainty.
• Date and implementation planning: Clear milestones accelerate implementation and ensure the start date.
• Interface clarity: Integrated layout and infrastructure planning minimizes risks in production, logistics and construction.
• Supplier management: Targeted research and inquiries strengthen quality and cost competition.
   

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Recording of machine waste heat loads and testing of waste heat utilization at HÖRMANN Automotive St. Wendel GmbH

Overview

Location: Sankt Wendel, Saarland, Germany
Project duration: 1 month
Energy consumption: approx. 6.1 GWh

HÖRMANN Rawema Engineering & Consulting GmbH successfully carried out the recording of machine waste heat loads and the testing of waste heat utilization for HÖRMANN Automotive St. Wendel GmbH. The aim was to reliably record waste heat sources, prioritize main consumers and identify reportable systems in accordance with the Energy Efficiency Act.

Project content

Sifting through and preparing the consumer list

Structured review and preparation of the consumer list. Creation of a consistent data basis for further recording and evaluation.

Prioritization of the installations to be recorded

Evaluation and prioritization of the installations according to expected waste heat loads. Focused measurement campaign with clear priorities.

On-site recording using a thermal imaging camera

Measurement-based recording of waste heat loads directly at the installations. Identification of hotspots and verification of existing data.

Evaluation and derivation of waste heat output

Analytical evaluation of the measurement data and derivation of the waste heat output per system. Quantification of the waste heat potential with approx. 400 MWh/a as a basis for measures.

Consolidate results and prioritize main consumers

Consolidation of the results into an overall picture. Prioritization of the main waste heat consumers for targeted efficiency and utilization approaches.

Examination of waste heat utilization and regulatory reconciliation

Evaluation of possible utilization options for the recorded waste heat. Comparison of potentially reportable systems for the site in accordance with the Energy Efficiency Act.

Transparent documentation

Traceable documentation of the methodology, results and priorities. Basis for decisions and further planning steps.

Advantages of our solution

• Transparent data basis: Measurement-based recording and structured evaluation create a reliable basis for decision-making.
• Target-focused prioritization: Clear identification of the main waste heat consumers enables effective measures to be taken first.
• Regulatory compliance: Alignment with the requirements of the Energy Efficiency Act reduces compliance risks.
• Sustainability: Exploitation of waste heat potential supports resource conservation and CO₂ reduction.
• Decision certainty: Consolidated results and clear documentation accelerate implementation.
   

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Recording and determination of the waste heat loads in the entire plant near Brand-Erbisdorf

Overview

Location: Brand-Erbisdorf, Saxony, Germany
Project duration: 52 months
Production area: approx. 26.000 square meters

HÖRMANN Rawema Engineering & Consulting GmbH successfully recorded and determined the waste heat loads in the entire plant at the Brand-Erbisdorf site. The aim was to record waste heat sources transparently, quantify loads reliably and transfer the results into a waste heat register.

Project content

Sifting through and structured preparation of the existing plant lists and technical data sheets. Creation of a reliable data basis for further evaluation.

On-site recording using a thermal imaging camera

Recording of waste heat loads directly at the plant using a thermal imaging camera. Identification of relevant hotspots and verification of the documented plant data.

Visualization of waste heat sources

Processing of the results in clear presentations. Clear overview of sources, intensities and spatial distribution of waste heat.

Evaluation by plant, area and hall

Determination of waste heat output per plant, functional area and hall. Quantification of the waste heat potential of approx. 27,000 MWh/a as a basis for evaluating measures.

Transfer to the waste heat register

Structured entry of all results in the waste heat register. Ensuring the traceability and ongoing maintenance of the data.

Data supplementation and support

Support in determining additional data required for the cadastre. Coordination with specialist departments for completeness and quality assurance.

Advantages of our solution

• Transparency: Visualized results and a structured waste heat register create a clear basis for decision-making.
• Regulatory certainty: Measurement-based verification supports compliance with the Energy Efficiency Act and other requirements.
• Targeted measures: Quantified loads per plant and hall enable prioritization of efficiency and recovery projects.
• Sustainability: Identified waste heat potential promotes resource conservation and CO₂ reduction in the plant.
• Planning reliability: Clean database reduces risks and accelerates the implementation of optimization measures.
   

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