Turnkey Assembly Lines
With assemblean's turnkey assembly lines, you get a consistently coordinated overall solution that seamlessly connects all project phases. We coordinate the operational, technical, and legal execution of your project and ensure the smooth integration of all components. From the first 3D layout to final production support on your shop floor, you receive a fully integrated system from a single source.
The decision between in-house integration and a turnkey solution is primarily a question of risk management and internal resource allocation. The following matrix illustrates how responsibilities shift.
| Analyse-Parameter | In-House Integration (Internal Engineering) | Split Trades (Multiple Vendors) | Full Turnkey System (assemblean) |
|---|---|---|---|
| Contract Partner | Numerous (component manufacturers) | 3–5 main vendors | Exactly one general contractor |
| Interface Risk | 100% with the operator | Gray zone between trades | 100% with assemblean |
| Guarantee Basis | Component level only | Module level | Overall Equipment Effectiveness (OEE) & cycle time |
| Legal Role (CE) | Operator becomes the "manufacturer" | Complex delineation required | assemblean delivers system-wide CE |
| Resource Commitment | Extremely high (ties up engineering teams) | High (requires project management) | Minimal (focus on milestone approvals) |
At the heart of our turnkey approach is the technological and organizational integration of cross-disciplinary systems. We proactively resolve the four critical interfaces of modern industrial plants.
We ensure the seamless physical flow of components. Whether high-speed transfer systems, precision pallet circulation systems, or millimeter-accurate positioning at machining stations — the entire kinematics are geometrically and dynamically coordinated in a central 3D model.
No more proliferation of disparate control architectures. Our turnkey systems are built on a unified hardware design. Sensors, actuators, and drive controllers use standardized bus systems, drastically simplifying your future spare parts management.
A turnkey line must not be a black box in your IT landscape. We develop native interface architectures that deliver machine data (cycle times, fault messages, process values) in a structured way via standardized protocols such as OPC UA directly to your MES or ERP.
When individual machines are linked together, they legally constitute a "machinery ensemble." As general contractor, we conduct the overarching risk assessment to DIN EN ISO 12100, develop the comprehensive safety concept (emergency stops, guard interlocks), and issue the final CE declaration of conformity for the entire line.
The nominal acquisition cost of a turnkey plant is logically higher than the sum of individual components. However, the business reality shows that the approach pays off massively through reduced total lifecycle costs (TCO) and accelerated time-to-market.
While in-house integration often loses months in unstable trial operation, our standardized commissioning process delivers a steep production ramp-up curve. Every delay in market introduction costs direct revenue potential.
Internal capacities in your engineering and IT departments remain available for your core business instead of being tied up troubleshooting on the shop floor. Resource deployment becomes predictable and is fully transferred to assemblean.
The homogeneous system architecture and a comprehensive diagnostic concept significantly reduce mean time to repair (MTTR) in subsequent series production. A single point of contact accelerates every service response in the event of a fault.
Process
A clear flow, one point of contact, and a well-coordinated manufacturing process.
Joint definition of all process requirements, cycle times, quality criteria, and interfaces. The result is a binding, frozen specification as the contractual basis.
Interdisciplinary review of all subsystems (mechanics, electrical, software) by our engineering team together with your specialists. Manufacturing only begins after your formal approval.
Mechanical and electrical assembly of the entire plant at our facility. Pre-commissioning of all subsystems under controlled conditions before your product is introduced.
Complete test of the plant under real production conditions at our facility. The contractually agreed throughput and quality targets must be reproducibly demonstrated here for the first time.
Professional disassembly, transport, and recommissioning in your production hall. Integration into your existing infrastructure, utilities, and IT systems.
Final Site Acceptance Test under real conditions in your production environment. Handover only after demonstrated achievement of all agreed performance parameters, including comprehensive operator training.
Leave the risks of plant engineering to the experts. Let us analyze how we can translate your product-specific processes into a turnkey, highly efficient overall system. Contact us for a well-founded, practical initial consultation.
FAQ
Since assemblean acts as general contractor, the functional risk lies entirely with us. If the agreed performance (e.g., parts output per minute at a defined good-part rate) is not achieved at the Site Acceptance Test, we are contractually obligated to rectify this at our own cost. You bear no technological risk.
Changes to the product being assembled are not uncommon during an ongoing project. Through our structured change management, we evaluate the impact of product changes on the plant layout, cycle time, and sensor systems within a few days.
You receive a transparent decision proposal regarding cost and timeline impacts before the change is implemented.
Yes, this is a standard procedure. If you already have functioning test stations, special tools, or cleaning systems, we integrate these mechanically, electrically, and software-wise into the overall concept.
We define clear handover interfaces in advance (signal exchange, pallet geometry) and integrate these components into the overarching safety concept.
You receive comprehensive, standards-compliant documentation. This includes the CE declaration of conformity for the entire plant, fluid and circuit diagrams, mechanical assembly drawings (including wear parts lists), software source codes (subject to contractual agreement), operating and maintenance manuals, and validation documents (particularly in regulated environments such as medical technology or automotive).
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