Video Fa. Handtmann promotional film Kechnec plant Photos: Source: Project engineers or Handtmann promotional film

Background

Albert Handtmann Metallgusswerk GmbH & Co. KG manufactures aluminum and magnesium parts for the automotive industry using die casting or gravity casting processes. Handtmann plans to build a die casting plant for housings and structural components in Kechnec (near Kosice, Slovakia). The new plant will implement state-of-the-art manufacturing concepts and can be expanded in a modular fashion. 

Handtmann commissioned Projektingenieure (PI) with the design and detailing of the new plant.

Result

• Factory for aluminum die-cast parts put into operation
• Layout for modular growth and separate truck and personnel traffic 
• Fully automated, fully interlinked production 
• Scalable capacities, flexible growth possible in different production areas 
• Implementation of the highest requirements for occupational safety, environmental protection, and energy efficiency

PI services

Factory planning, process planning, logistics planning

Concept design 
analogous to VDI 5200, phases 1 to 3

• Capacity requirements, material flows, and logistics areas simulated in scenarios 
• Production segments defined 
  • Smelting: shaft furnaces 
  • Foundry: fully automatic casting cells for die casting machines up to 35 MN 
  • Blasting: continuous blast system 
  • Mechanical processing: fully interlinked, including machining, high-pressure cleaning, leak testing, etc. 
  • Tool and machine maintenance 
  • Measuring rooms, laboratories 
  • Office and social areas, energy and media supply, 
• IT networks 
• Logistics concept (material flow, staging areas, conveyor systems, storage systems) created 
• Layout start and modular extensions created 
• Resources (personnel, equipment, buildings, infrastructure) dimensioned 
• Investments determined 
• Master plan for implementation created

Detailing 
analog VDI 5200, Phasen 4 und 5

• Detailed manufacturing segments 
• Machine layout plan created 
• Piping and instrumentation diagram (P&ID) for media supply and disposal created 
• Construction and infrastructure requirements specified (specifications) 
• Budget and schedule created

Topics

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: Simulation of movements/inventories, conveyor technology: Storage technology/transport technology, fire protection

Trades

Charging, melting, dosing, casting, spraying, removing, cooling, deburring, burr disposal, marking, cleaning, blasting, testing, mechanical processing, leak testing, impregnation, packaging, transport, storage; automation, interlinking buildings, pits, foundations, ventilation technology, cranes, media, infrastructure