The largest new construction project in the history of Bausch + Ströbel is functional, lean, and impressive

In order to secure its competitive position for the future, special and packaging machine manufacturer Bausch + Ströbel commissioned Ingenics to develop a multi-stage general development plan under the name “Bausch + Ströbel 2020” in 2008. Part of the program was the design and realization of a new plant building at the company headquarters in Ilshofen. Following a holistic analysis of the company by Ingenics, the new office building was completed in the first phase of expansion, receiving an enthusiastic response at the official opening ceremony in the summer of 2010. In the second stage of development, which ended in the middle of 2012, a three-part building was erected with a total area of 13,500 sq m. In addition to a modern assembly hall, this offers room for a spacious picking warehouse, side rooms for seminars or discussions with customers, offices, and a canteen that can seat some 200 people.

All of the requirements for the new plant were defined in advance with the management team at Bausch + Ströbel. The following aspects were the main areas of focus:

• Impressive architecture in keeping with the pharmaceutical industry that meets customer expectations in every respect.
• Optimization of all processes and implementation of the lean philosophy through a streamlined material flow, short distances, and the perfect organization of jobs.
• A strict focus on function with respect to the floor space concept in the assembly and picking hall.

As a result of the second stage of the general development plan, Bausch + Ströbel gained some 5,000 sq m of space in the new assembly hall alone. Individual module solutions were necessary here in order to accommodate special assembly requirements arising from the manufacturing of packaging machinery. The specified installation plan proved to be a real challenge – one that was successfully overcome – because each system had to be configured according to the original design for acceptance by the customer.

The directed flow of materials is crucial when it comes to sustainably increasing efficiency through optimized processes. For that reason, all operations leading directly to the goal – from production and pre-assembly to final assembly and machine shipping – follow the rules of lean philosophy. A new overhead crane smoothly and efficiently transports modules through the hall.

Since the regular presence of customers on-site places special demands on its overall appearance, the decision was made to use shiny surfaces that are easy to keep clean as well as high-tech elements, which also happen to be very popular among employees. The generally pleasant working atmosphere at Bausch + Ströbel is now completed by a constantly low noise level and a generous amount of daylight.

Both customers and staff can feel comfortable in the new L building, which covers around 3,700 sq m in the heart of the site. In particular, the open architecture of the grand upper floor with its rooftop terrace impresses visitors to the company restaurant, while the training and conference rooms also signal a warm welcome. For the parts picking warehouse on the first floor, however, functional requirements and the optimized flow of materials are in the foreground.

The third building, the final section to be completed, provides offices and meeting rooms for senior engineers and customers, all in close proximity to the production site with floor space of approximately 3,400 sq m. The latest stage of development was completed with a covered visitor route that guides customers and visitors to their destination following the shortest possible path – also in line with lean philosophy.

The management team at Bausch + Ströbel and the consultants from Ingenics agreed from the outset that an energy-efficient design was a priority. The site features environmentally friendly ventilation systems with highly efficient heat recovery and a sustainable roof design with solar panels.