Background

Nemak is a leading manufacturer of aluminum castings for the automotive industry. In February 2026, Nemak expanded its portfolio by acquiring the automotive division of Georg Fischer (GF) Casting Solutions. 

Immediately prior to this acquisition, GF had built a greenfield foundry for structural components for its customer BMW in Augusta, Georgia (USA). 

GF commissioned PI to handle everything from the design to the implementation of this foundry.

Results

• Factory put into operation
• Fully automated production
• Standardised production cells with casting cells DCM 61 MN
• Implementation of the highest standards of occupational safety, environmental protection and energy efficiency
• On-time construction

Services PI

Factory planning, process planning, logistics planning

Concept design
analogous to VDI 5200, phases 1 to 3

• Manufacturing segments and organization defined
  • Smelting: Shaft melting furnaces specialised for return material from large structural parts, testing laboratory, furnace workshop
  • Foundry: Fully automatic casting cells with die-casting machines 61 MN, deburring station, cleaning/sawing cell, blasting system, etc.
  • Heat treatment 
  • Automatic straightening
  • Fully automatic deburring
  • Mechanical processing
  • Passivating line
  • Tool and machine maintenance
  • Measuring rooms, laboratories
  • Office and social areas, energy and media supply, IT networks
• Logistics concept (material flow, conveyor systems, agv, warehouse sizes) created
• Resources (personnel, equipment, buildings, infrastructure) dimensioned
• Rough concept for plant development created
  • Investments, costs
  • Layout Start and gradual expandability
  • Master plan for implementation

Detailing
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments
• Machine layout plan created
• R+I diagram for media supply and disposal created
• Requirements for construction and infrastructure specified (specifications)
• Tender for construction and infrastructure accompanied, quotations obtained and prepared for award
• Supported the client in selecting the general contractor (for construction and infrastructure)
• Interfaces with engineering offices for construction and technical development serviced
• Budget and schedule created

Implementation
analogous to VDI 5200, phases 6 and 7

• Details agreed with suppliers
• Interfaces with customers (planning, production, maintenance) and other suppliers or service providers (construction, media, crane service, etc.) coordinated, solutions developed
• Proper provision of individual services monitored and controlled
• Support provided to client during factory start-up
• Overall layout updated
• Budget (investments) tracked

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, load carrier design, conveyor technology: Warehouse technology/transport technology, fire protection

Trades

Charging, melting, dosing, casting, spraying, cooling, deburring, burr disposal, marking, cleaning, heat treatment, testing, straightening, mechanical processing, passivation, packaging, transporting, storing; automation, interlinking Buildings, pits, foundations, ventilation technology, cranes, media, infrastructure