Restructuring and successful commissioning of a semi-automated welding station for Endress+Hauser

scope

This project involved responsibility for the commissioning of a semi-automated welding station. The focus was on structured project management with clear control of all technical and organizational measures to stabilize and complete the plant.

The main tasks included planning the commissioning and technical upgrading of the station. In addition, all quality approvals were prepared, coordinated, and carried out. An integrated overall schedule with continuous tracking ensured transparency regarding progress, risks, and dependencies.

In addition, the scope of services included supplier management, regular reporting to management—including top management and the executive board of Endress+Hauser—as well as planning and overall responsibility for the start of production.

Project details:

Sector: Special machine construction / measurement and automation technology

Client: Endress+Hauser

Location: Reinach (Switzerland)

Undertaken by: Waldemar Graf, Rolf Thelen

Time period: February 2020 – August 2022

At the time of commissioning, the welding station was already in operation at the Reinach site. However, the project was several months behind schedule and had reached a standstill.

Key project parameters were unclear, progress was not documented transparently, and overall management was only effective to a limited extent. There was effectively no longer a reliable basis for the structured continuation of the project.

The objective was to completely redesign and restructure the project in order to restore efficient and targeted project management. Clear responsibilities, transparent control mechanisms, and realistic scheduling and action planning were intended to stabilize the project and bring it to a successful conclusion.

The project had already been delayed for several months, the budget had been exceeded many times over, and the overall situation was highly opaque. The project team was understandably frustrated and demotivated.

In addition, pronounced internal conflicts of interest on the customer side made the situation considerably more difficult. Decision-making processes were highly politicized and delayed necessary measures. The project was on the verge of being abandoned—including consideration of scrapping the entire plant.

Through consistent restructuring and clear project management, the project was successfully stabilized and resumed. The commissioning and technical upgrading of the welding station were successfully completed.

All quality inspections were positive, production started up as planned, and the plant was successfully transferred to series production.

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