Starting basis:

• Existing fresh air concept no longer sufficient due to system expansion

• In summer up to 40 ° C in the manufacturing area

• Fresh air supplied below the roof, thereby pushing warm air down

• New concept had to be created

• In addition, effective cooling without additional energy costs should be considered

• Warm exhaust air should be collected and used for heat recovery

• The right mix of fresh air and warm indoor air should be prepared for the  winter time

• Fresh air should be fed on a low level to encourage the warm air to vent upwards

• Additional fresh air pipes should be implemented

• Precise design should be created to take all areas into account

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Approach:

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Starting basis:

• production equipment had to be relocated from Germany to China

• Special machining center (which could theoretically manufacture weapons)

• Coating line with a length of 40 m (necessary gas connection, only from authorities)

• Some new equipment purchases were made in Germany and had to be imported later

• Accordingly, documentation had to be issued correctly to avoid delays

• Many production equipment needed to relocated after the expansion of the plant

• In coordination with the customer, equipment supplier, possibly relocation company, if it could not be implemented

• Relocation with clean rooms

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Approach:

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Starting basis:

• There were official requirements from government to cultivate the unused land

• In addition, there were many new projects in the pipelines

• Manufacturing areas in the existing areas were already at the limit

• External storage costs should be reduced

• Tool making should be expanded to serve other plants in Asia and the USA

• Tool making had to be specially conditioned

• Storage space should be set up in a small area

• Waste areas should be newly and properly integrated

• EX mixing room had to be set up, this was not available in the existing building

• Social rooms had to be expanded because the number of employees increased enormously

• Offices had to be expanded for the same reason

• Server rooms also had to be set up to protect the loss of data

  • There were no rooms in the existing building

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Approach:

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Starting basis:

• There were originally no specifications for this

• This project was initiated by my self

• A lot of waste heat was produced in the factory due to additional production equipment

• It was difficult to remove the waste heat

• In winter, expensive district heating had to be purchased

• 1. Approach collects the heat through a heat pump to concentrate the heat and return it to the building, especially in winter

• 2. Approach, heat should be stored underground in summer so that it can be used in the transition months

• High energy savings through own heat supply have to be achieved

• District heating was no longer needed and all the energy cost could be saved completely

Approach:

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Starting basis:

• Purchases of new equipment were not specified correctly and timing not controlled

• Price negotiation with suppliers was insufficient

• Spare parts packages were not considered when purchasing

• Acceptance of the systems was not done via CPK / CMK / SPC's and often arrived at the factory in poor conditions

• Task was assigned to me because I already had experience in this regard

• Specifications should be revised, mostly in cooperation with production, tool making, QA, suppliers, etc.

• Time schedule had to be prepared and tracked

• Release of new suppliers had to be done

• System providers had to be located, especially robots, special assembly machine, etc.

• Many systems should be automated

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Approach:

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Starting basis:

• Processes should be automated

• Stuff should be reduced

• Processes should be optimized

• This should improve quality standards

• Processes had to be redesigned

• Cycle times reduced

• Output had to be increased

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Approach:

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Starting basis

• Many machines did not meet the safety standards

• There was a risk of injury

• All processes should be considered

• Old laser marking systems were dependent on the employee

• Light barriers were not checked

• Light sensors did not cover the entire area

• Order and cleanliness was not kept

• A customer-friendly standard should be established via 5S

• Waste management was not managed properly

• Environmental regulations had to be complied with

• Accident statistics were not kept

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Approach:

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