Background

Piller Blowers & Compressors GmbH ("Piller") develops, manufactures, and distributes high-performance blowers, compressors, and steam compressors for the food, chemical, and textile industries. The main plant in Moringen is to be restructured and expanded on the company premises to accommodate planned growth. 

Piller commissioned Projektingenieure (PI) with the design and detailing of this expansion.

Results

• Layout for modular growth
• New construction 
  • Production hall for assembly, testing, and shipping 
  • Logistics hall 
  • Office and social building
• Production structured according to component manufacturing and assembly, with spatially separated cleanliness areas
• Matrix structure according to product lines and process steps in the areas of assembly, cabling, testing, and insulation
• Plant structure for consistently separate truck and personnel traffic
• Energy-efficient production hall with underfloor heating, heat generation via heat pump, and electricity generation via solar panels
• Implementation of the highest standards of 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
• Manufacturing segments defined
  • Welding impellers and housings 
  • Machining 
  • Blasting 
  • Painting 
  • Assembly 
  • Testing 
  • Packaging
• 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
analogous to VDI 5200, phases 4 and 5

• Detailed manufacturing segments
• Machine layout plan created
• R+I diagram for media supply and disposal created
• Planning services for construction planning (architect, structural engineer, etc.) and technical building services (heating, ventilation, sanitation, electrical, fire protection) specified (specifications) and put out to tender
• Support for construction and building services planners until submission of the approval plans
• 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: Plant engineering, assembly technology, 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

Welding cell, machining centers, paint shop, test benches, sound measurement tracks, 40-ton gantry cranes, 16-ton semi-gantry cranes, compressed air center, ventilation technology, transformer station