Introduction
A global OEM intended to fully modernize an idle production hall in the heart of Russia in order to produce two-stroke engines. The plan was to produce between 1,000 and 2,000 engines for snowmobiles and ATVs (All Terrain Vehicles) a month.

The customer entrusted a team from IndustrieHansa, ideally suited to the work as a result of successfully realizing projects with similar requirements, with analyzing and producing a design concept for the engine factory.

Solution: The engineering team from IndustrieHansa investigated two production strategies with different levels of automation, evaluated them from both a quantity and quality perspective and gave a recommendation on this basis.

Puncture points

• Surveying current situation and analysis in the categories of Parts Production, Facility Functions, Organization, Cost Structure and Interim Meeting
• Design concept and development of two production strategies with different levels of automation (highly and partly automated)
• Evaluation and planning of the production and assembly departments, infrastructure and logistics
• Examination and assessment of structural requirements
• Production of a logistics concept including material flow planning
• Initial concept for the flow of data within the production control system
• Time analysis and staff planning
• Production and presentation of a comprehensive factory concept and the infrastructure needed for production
• Analysis and evaluation of greenfield and brownfield land
• Cost estimate, rough date planning and supplier recommendation
• Project management in implementing the concept

Benefits
The customer's specifications for efficiency, emissions and process design were exceeded by 10%. State-of-the-art lean logistics and lean production tools were integrated in both concepts. They proved to be some of the main reasons for the customer's great satisfaction with the project.

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