Background

GE Energy is a leading manufacturer of highly efficient wind turbines. Its standard turbines are designed for onshore applications in the 1.5 to 5 MW power range. GE is developing a 6 to 10 MW wind turbine for offshore applications and is planning its industrialization at the same time.

GE Energy commissioned PI to design the assembly plant for the new offshore wind turbines, including the necessary supply chain.

Results

• Phased station assembly with coordinated pre-assembly
• Logistics concept for supplying the factory with components
• Means of transport, lifting aids, platforms, and devices for the necessary heavy-duty assembly work
• Layout (3D) showing the assembly process and derived definition of building and infrastructure requirements
• Required investments and implementation schedule

PI services

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Assembly process defined with synchronized assembly contents per station and coordinated pre-assemblies (assembly priority graph)
• Supply warehouse > Order picking > Assembly stations simulated and designed: Control principles, buffers/inventories
• Means of transport, lifting aids, platforms, and devices designed for necessary heavy-duty assembly work
• Logistics concept (material flow, staging areas, conveyor systems, storage systems) created
• Layout created
• Resources (personnel, equipment, buildings, infrastructure) dimensioned
• Investments determined
• Master plan for implementation created

Topics

Process design: Manufacturing site, footprint

Factory planning: Value stream, production segments, material flow, layout, scalability, step-by-step expansion, facilities/infrastructure/buildings, cleanliness, environmental protection

Process planning: Process engineering, plant engineering, simulation of capacity requirements, automation, interlinking, energy efficiency, IT, control technology, machine and process data acquisition, Industry 4.0

Logistics planning: Material supply strategy by part, simulation of movements/inventories, load carrier design, load carrier design, conveyor technology: Warehouse technology/transport technology, order picking technology, fire protection

Trades

Assembly stations, assembly trolleys, cranes, hoists, fixtures, tools, storage systems, heavy-duty storage, supermarket, transport systems, logistics train, production buildings, offices, social rooms