Background

PCI Augsburg is a leading manufacturer of construction chemicals with annual sales of over €200 million. PCI is part of BASF SE. The existing production of silicone and polyurethane joint sealants is to be relocated to the new federal states. PI was commissioned to develop and implement a greenfield concept for the new plant.

Results

• Factory commissioned, capacity expansion
• Significant increase in productivity
• Compliance with strict environmental requirements

PI services

Factory planning, process planning, design During the design phase, PI worked with the customer to develop, among other things:

• New manufacturing process (manufacturing method) designed
• Manufacturing segments and organisation defined
• Logistics concept (material flow, storage and conveyor systems) created
• Resources (personnel, equipment, buildings) dimensioned
• Plant development designed
  • Investments, costs
  • Layout of new factory
  • Master plan for implementation

Detailing
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments and islands
  • R+I diagram for media supply and disposal created
  • Machine layout plan (1:100) created
  • System list created
  • System technology specified
• Storage and conveyor technology specified
• Explosion protection measures designed and detailed
• Plant, storage and conveyor technology tendered and prepared for award
• Buildings and technical systems specified
• Engineering firms requested, selected and involved
  • Architect and structural engineer
  • Heating/ventilation/plumbing
  • Expert (soil, fire protection)
• Prepared approval documents (construction, Federal Immission Control Act) and obtained approval
• Prepared budget and schedule, established project controlling

Implementation
analogous to VDI 5200, phases 5 and 6

• Supplier performance monitored and approved
  • New building construction and technical systems 
  • Installation/integration of newly procured equipment
• Engineering offices managed (senior site management)
• Budget (investments) monitored

Topics

Technology: Value stream, production segments, manufacturing processes, material flow, layout, plant engineering, control and monitoring technology, media supply and disposal, warehouse technology, conveyor technology, BDE, MDE 

Processes: Production organization

Trades

Dosing technology, mixers, filling plant, silos, tank and rack storage for raw materials, media supply, production and rack storage, explosion-proof, production hall, offices, laboratory, and social rooms