Background

Siemens is a leading manufacturer of electric motors. The manufacturing network is being restructured. The plant in Mohelnize, with 2,300 employees, is taking over products from other locations. Additional growth is planned. The location is largely organized according to tasks. Control is complex. SIEMENS plans to divide the plant into four independent factories based on processes: a runner factory, a variant factory, a component factory, and a foundry. 

PI was commissioned to redesign the four factories within the existing buildings and to detail the runner factory.

Results

• Variant tree created and analyzed at component level for subsequent division of factories 
• Production content and capacity requirements determined for each factory 
• Logistics concept (material flow, control principles, inventories, and conveyor systems) created 
• Production islands designed with flow principle and U-shape 
• Personnel requirements dimensioned 
• Layout and material flow for the new structure designed 
• Investments, personnel requirements, and inventory changes determined 
• Economic efficiency (cash flow statement) estimated 
• Schedule for implementation determined

PI services

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Variant tree created and analysed at component level for subsequent division of factories
• Production content and capacity requirements determined for each factory
• Logistics concept (material flow, control principles, inventories and conveyor systems) created
• Production islands designed with flow principle and U-shape
• Personnel requirements dimensioned
• Layout and material flow for the new structure designed
• Investments, personnel requirements and inventory changes determined
• Economic efficiency (cash flow statement) estimated
• Implementation schedule determined

Detailing
analogous to VDI 5200, phases 4 and 5

• Structural and procedural organisation redefined: 4 factories and 2 service areas
• Staff allocated to new structure
• Logistics simulated, control and Kanban circles defined
• Specifications for SAP adaptation provided

Success Factory

• Inventory and warehouse dimensions
• Detailed storage, picking and transport processes and techniques
• Detailed assembly islands (U-shape, flow production, cycle time, waste-free workstations, etc.)
• Layout, material flow and work processes in detail
• Requests created and quotations obtained
• Investments and personnel requirements in detail
• Profitability (cash flow statement) calculated
• Schedule for implementation determined

Topic

Product design: Variant management

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

Logistics planning: Simulation of movements/inventories, load carrier design, conveyor technology: Warehouse technology/transport technology, order picking technology, fire protection

Trades

Punching, die casting machines, packaging machines, winding and insertion machines, machining and assembly cells, testing cells, storage technology, logistics train, impregnation systems, painting systems, Power&Free conveyor technology