Application Technology

The new German production site is based in Weil am Rhein close to the German-Swiss-French border.

Five years in the making, the new production building covers 43,000m2 and includes the entire manufacturing chain for metallic goods – from receiving raw materials to delivering the merchandise – including prefabrication, heat treatment, and surface treatment. Some 350 employees have left various German operartions spread throughout Lörrach to work at the new site.

“We have built this new production facility, the largest factory in the ARaymond network, to help us modernise,” explains Jürgen Trefzer, CEO at ARaymond GmbH & Co KG in Germany. “We are looking to provide even more value added to our partners and to offer our employees more comfortable working conditions.”

Overall investment totalled €55 million, with the construction of the building costing €41 million and the remaining €14 million put towards facilities, operating equipment, and the outdoor facilities.

The new manufacturing site includes 20,000m² of production area, 4,000m² of storage space for raw materials, 2,500m² of tools and maintenance area, 850m2 of canteen area, and 850m² of office space. The new factory will exclusively manufacture metal fasteners and the complete line of ARaymond metal clips – made on deep-drawing presses and press brakes – for equipment manufacturers and tier 1 suppliers.

The production area has been divided into two 10,000m² production spaces, with each only having six and eight supporting pillars respectively – leaving as much space as possible for production. The first production area is for pieces regularly ordered by customers, and the second is for ‘rarer’ pieces that are typically needed just once or only occasionally.

All machinery has been equipped with individual intake and output ventilation and soundproofing. To achieve this, an extensive ventilation and energy efficiency concept had to be developed. In addition, ARaymond has improved the ergonomics of the workstations by optimising the collection of press waste. A vacuum conveyor system is connected to every press and automatically transports all scrap to a central conveyor – attached to the ceiling – that takes it to a repurposing point. The need to manipulate the heavy and sharp scraps has therefore been reduced as much as possible.

“We have been able to improve the quality and ergonomics of our workplaces for our employees significantly,” comments Jürgen Trefzer. “Before we started the design of the building, we developed several main objectives to optimise the layout, as well as working conditions and sustainability.”

Optimising the flow of materials: The goal was to create a clear circuit for goods and components and use internal logistics to avoid trips where no goods are transported and to avoid duplicating tasks. To do this, ARaymond collaborated with the IFA – the Hannover Institute for Planning Sites and Factories – in order to adapt the building to an agreed layout.

Managing employees: Another requirement of management was to create optimised workstations for employees while maintaining a good working atmosphere. The workstations are therefore well-lit, large enough and in airy spaces. Moreover, the manufacturing area includes a production cell dedicated to initial and continued training.

Transparency: Despite the building’s size, everything was done to shorten the lines of communication and ensure open and transparent structures that allow for dialogue, listening, and discussion.

Adaptability: The building was designed to guarantee almost infinite modularity so it can be adapted to coming changes in production technologies. The production cells are therefore modular. The machines can also be quickly and easily modified.

Durability: Originally the building was designed to comply with the LEED silver construction principles – an American certification for sustainable and environmentally friendly buildings. However, after applying these objectives to its new building, ARaymond received the LEED Gold certification.