Background

Gerresheimer Bünde GmbH is a leading manufacturer of primary packaging made of glass or plastic (droppers, syringes, bottles, etc.) for the pharmaceutical industry. The group subsidiary generates sales of approximately €120 million per annum. The product portfolio is to be renewed in line with market requirements, and sales are to be doubled in the medium term. Production has grown gradually, resulting in a highly fragmented and technically outdated facility. The increased focus on the pharmaceutical industry requires an expansion of the high quality standards. PI was commissioned to completely redesign the plant, including its production structure and organization, and to implement the concept.

Results

• Plants put into operation
• Capacity expansion with adaptation to the new product structure at (pharmaceutical) quality level
• Significant increase in productivity
• Improved working conditions

PI services

Factory planning, process planning, logistics planning 

Concept design
analogous to VDI 5200, phases 1 to 3

• Production segments and organisation defined
• 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
• Improvement measures that can be implemented in the short term identified

Detailing
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments and islands
  • Machine layout plan created
  • Piping and instrumentation diagram (P&ID) for media supply and disposal created
  • Equipment list created
  • Plant technology (including clean room technology) specified
• Storage and conveyor technology (raw materials, semi-finished products) specified
• Plan for implementing the systems during ongoing operations created (migration)
• New development of a packaging and packing line managed
• Outsourcing of outbound logistics (finished goods warehouse + order picking) specified, put out to tender and prepared for awarding
• Interfaces to the logistics service provider defined
• Plant technology put out to tender, quotations obtained and prepared for award
• Buildings and technical systems specified
• Engineering firms requested, selected and involved
  • Architect and structural engineer
  • Heating/ventilation/sanitation
  • Clean room technology
  • GMP consultant
  • Expert (soil assessor, noise protection)
• Approval documents prepared
• Budget and schedule drawn up, project controlling established

Implementation
analogous to VDI 5200, phases 6 and 7

• Managed supplier performance, organized acceptance procedures
  • New construction of halls, office buildings, social facilities, technical systems
  • Assembly/integration of newly procured systems
  • Relocation/integration of existing systems
• Outsourced logistics outbound
• Managed engineering firms (senior site management)
• Monitored budget (investments)

Topics

Process design: Process cost calculation

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: Conveyor technology: Warehouse technology/transport technology, fire protection

Trades

Glass forming lines, assembly lines, assembly islands, automation, interlinking, clean rooms, storage and transport systems, ventilation and media supply, production halls, office and social rooms