Walls straight off the line – Munich Consulting Group

Walls straight off the line.

Redbloc Elemente GmbH, based in Plattling in Lower Bavaria, is rethinking how we build with brick: instead of laying brick on brick, complete brick walls are produced here as prefabricated elements, fully automated, course-accurate and with carbon reinforcement embedded along the way. From the first brick on the pallet to the finished, bonded wall, the line handles every step. Together with Munich Consulting Group, this existing plant was captured, assessed and made tangible in its real performance for the first time.

At a glance.

The challenge

A fully automated production line, grown over the years across many separate trades, needed to be understood as a whole, from depalletising through sawing, drilling and bonding to wall cutting. What does the system actually deliver, and where are the steps that set the pace?

Collaborative solution

Together with Redbloc, MCG captured the plant on site component by component, documented processes and cycle times in live operation, and built a sound performance assessment around a real sample wall.

Achievement

A complete, traceable picture of the plant, from the individual component to the throughput time of a finished wall element. A clear basis on which the operation, optimisation and further development of the automated production can be built.

The challenge

There is no second automated wall production line for brick quite like this one, and that is exactly what makes it hard to grasp. Over the years, robots, conveyor lines, sawing centres, vertical and horizontal drilling, the bonding station and the wire saw had grown into a tightly interlocked overall system whose individual parts came from very different sources. The task: to understand this system in its entirety, describe every part of the plant cleanly, and ultimately give an honest answer to the real question, how much wall is actually produced here, and in what time?

A one-of-a-kind plant, measured objectively.

Collaborative solution

Collaboration on equal footing means one thing to us: getting into the hall, not just looking at it from the outside. Together with the Redbloc team, we captured the plant step by step, documenting every component in photos and video and measuring every process in live operation. The result was not an abstract desk-based report, but a description that reflects the actual production flow. For the performance assessment, we deliberately chose a real sample wall from ongoing production and followed the entire path from the first brick to the bonded element. This brings together the know-how from the shop floor and the structured methodology of an end-to-end plant assessment.

From the first brick to the finished wall, captured without gaps.

Achievement

What remains in the end is an overall picture that makes the plant tangible from end to end for the first time: from the individual component and its performance data, through the individual cycle times, to the throughput time of a complete wall element in series operation. What becomes visible is not only what the system delivers, but also which step sets the pace for the entire production. This gives Redbloc a solid basis to work from, both as an objective proof of performance and as a starting point for the targeted further development of a production that redefines how we build with brick.