Reishauer AG – Planning and Execution of a Smart Factory with Vertical Production Flows
Reishauer AG is the global market leader in the development and construction of systems for the hard finishing of gears. IE Technology planned and executed a new production facility as General Contractor, turning the vision of a smart, vertical factory from theory into practice.
Liberation from Old Structures – A New Factory for the Global Market Leader
Project
Planning and Execution of a Production Plant as General Contractor – from Feasibility Study to Construction
Client
Reishauer AG
Key Data
Working Together for Project Success
Services provided by IE Group
- Planning and execution of a production plant as General Contractor
- From feasibility study to construction
- Evaluation of the optimal location
- Inside‑out planning based on the IE methodology, 3D BIM overall planning, and VR tools for virtual machine placement
- Precise climate control with a tolerance of ±1 K
- Effective vibration protection through special foundations
- Three construction stages over seven years during ongoing operation
Challenges & Solutions
Solid Foundations for a Reliable Project Decision
New Building During Ongoing Operation
High Operational Safety of Sensitive Production Plants
Vibration Prevention
The Project in Detail
Reishauer AG is one of the world’s leading complete solution providers for the gearing industry, and the global market leader in the development and construction of systems for the hard finishing of gears. The Swiss company’s high‑precision tooth flank grinding machines are used worldwide to manufacture gears for the automotive, aviation, truck, and robotics industries. As the production structures that had grown over decades reached their limits due to the company’s successful expansion, Reishauer commissioned the experts at IE Technology to plan and execute a completely new production facility.
The Challenge
To remain competitive in Switzerland, Reishauer AG sought to build a new production hall in Zurich for the manufacturing of high‑precision gearing machines. Various sites were evaluated, including variants in which the new hall could be built on the existing company premises with an extension. The particular challenges of this project involved stringent requirements for vibration damping and climate control to ensure the most stable building and production conditions possible.
Key Success Factors
The extremely demanding planning and execution requirements for the new production hall called for exceptionally close coordination across all planning disciplines. This holistic and iterative planning process is illustrated by the example of foundations resting on a high‑density gravel box that uses the ground as a natural vibration damper. A ventilation system was also developed that intelligently uses free night cooling combined with a highly insulated building envelope to achieve stable indoor temperatures. In addition, a special structural solution was created for the hall roof: the 36‑meter‑wide shed roof is supported by longitudinal girders. Thanks to the upstream delivery and crane zone, horizontally incoming crane loads could be absorbed by the girders without costly structural measures.
Deepen Your Knowledge
Discover further details in our Project Insight.