Ronal AG, headquartered in Härkingen, is a leading global manufacturer and supplier of light alloy wheels for cars and commercial vehicles. The production of aluminum wheels requires a series of process steps such as melting, casting, heat treatment, mechanical processing, painting, etc.
In order to increase production capacity by 40 % due to high demand, Ronal decided to plan and build a new, additional plant in Teruel (Spain).
Helbling supported Ronal in the feasibility study, in the concept and detailed planning and in the realization of the new plant. As a result, the new production plant was opened within 2.5 years, incorporating findings from the existing plants for optimization. The new plant was built in an industrial area on a greenfield site of approx. 55,000 m2. The production and intralogistics systems are highly integrated and automated.
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Key Figures
Our Contribution
- Development of feasibility study and concept planning for the new factory
- Development of an expansion plan for a gradual increase in capacity
- Carrying out material flow simulations (to check the feasibility and optimization of layouts and intralogistics)
- Preparation of the investment proposal
- Detailed planning of the operating layout and coordination of the interfaces to construction
- Preparation of the specifications for the operating
- Technical advice and coordination in the areas of construction and technical building equipment
- Participation in the preparation of the project manual
- Participation in the creation of the construction logistics concept
- Analysis and advice on various expert reports (Health, Safety & Environment)
- Advice on the preparation of the total contractor agreement
Outcome
- Production plant according to plan with short ramp-up time (incl. gradual expansion)
- Very short project lead time: from the start of the feasibility study to the start of construction in 12 months
- The estimated investment costs for the construction, the technical building equipment and the production and intralogistics equipment correspond very well with real costs
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