ALHO Production

The ALHO room factory

The room modules are prefabricated under constant conditions in a weather-protected workshop. This enables sustainable and resource-saving production with efficient use of materials. Residual materials are reused as far as possible, which reduces the amount of waste. Industrial production not only ensures consistently high quality, but also precise execution of all work steps, regardless of weather-related influences. The high degree of prefabrication considerably shortens the construction time on site. Concrete staircases and lift shafts are fully assembled in the production hall. The sanitary installation, including leak testing, is often already pre-installed or even completed.

The production department has the steel construction and interior construction departments, including subcontractor services for the production of the room modules, the team for loading the room modules and the teams for module assembly.

Procedure

The production of roof and floor frames forms the foundation of our modular buildings. In ALHO's metalworking shop, these frames are connected to prefabricated corner supports to create the stable supporting structure of the modules. They are then painted to provide corrosion protection.

The cutting centre is an important supplier for the steel construction and interior fittings departments. The required dimensions are determined beforehand by the "Measuring in interior construction" station and transferred digitally as an order to the sawing centre. The modern CNC-controlled horizontal panel saw then produces the required panel cuts with dimensional accuracy. This precise working method not only ensures a high degree of fitting accuracy, but also minimises material waste.

Once the basic construction of a module has been produced in the steel construction department, the step-by-step process to the finished room begins in the interior design department. Here, drywall builders, carpenters, plumbers, electricians, painters, screed layers and tilers work hand in hand. A fully equipped module is created from the robust steel frame. The fit-out follows a clearly structured process: Floor construction is followed by wall construction and panelling, then electrical and sanitary installations and the installation of windows and doors. Finally, the modules are prepared for transport to the construction site. Depending on the customer's wishes and the type of building, additional finishing stages such as screed, wall panelling or floor coverings are added.

Material logistics at ALHO ensures that all required materials are available just-in-time exactly where they are needed in each production step. Frequently used tools are allocated and made available to employees in mobile tool trolleys. Automatic tool dispensers (OrsyMats) are available at every station for special tools. A well thought-out and optimised material flow is at the heart of ALHO Lean Production. This avoids unnecessary waiting times due to missing material, speeds up work processes and makes production more efficient overall.

The ALHO assembly team begins assembly on site while the last modules are still being finalised in the factory. Assembly only takes a few days so that the building can be entered for the first time after a short time. Due to the high degree of prefabrication, assembly is usually quiet and clean.

Lean Production

Lean production aims to make processes as lean, efficient and resource-saving as possible. The aim is to avoid all types of waste while maximising value for the customer. The concept originally comes from the automotive industry, where it was developed and perfected by Toyota. The core idea is to optimise processes, minimise bottlenecks and coordinate production processes. In modular construction in particular, lean production ensures efficient planning and production of modules. Just-in-time deliveries ensure that components arrive exactly when they are needed, without long storage times or delays.