MONTECO INSIGHTS: Major Project for Greiner Bio-One GmbH

Success Story & Field Report

High performance during ongoing operations: MONTECO Industriemontagen GmbH has once again demonstrated its expertise in complex construction site management and cross-trade coordination. On behalf of Körber Supply Chain Automation GmbH, MONTECO supported a demanding retrofit project for the end customer Greiner Bio-One GmbH — delivering impressive results.

The Project: Modernization as Part of a High-Tech Retrofit

The major project at Greiner Bio-One GmbH involved the modernization, or retrofit, of the automated high-bay warehouse. A warehouse management and material flow control system that had been in operation for around 20 years was completely replaced by an integrated, future-oriented SAP LES solution, including a direct conveyor technology interface and a simulation-based material flow controller. In parallel, extensive roof refurbishment and fire protection upgrades were carried out in the warehouse area.

The Challenge: “Open-Heart Surgery”

The conversion work and integration tests had to be carried out during non-working hours at night and over the turn of the year, as the warehouse remained partially active throughout the project. Upon completion of the modernization, the performance of the high-bay warehouse was doubled.
At peak times, up to 70 logistics and installation experts from five different suppliers were working on site simultaneously. Numerous specialist departments worked continuously to keep production stable throughout the entire project duration.

MONTECO’s Scope of Services: Precision and Coordination

To ensure that such a tightly scheduled and critical project could be completed safely, on time and efficiently, MONTECO Industriemontagen GmbH assumed full responsibility for managing, monitoring and safeguarding all activities on the construction site. The scope of services included:

InfrastruktInfrastructure & Site Setup:
Independent preparation of the construction site setup plan, covering production, transport and storage facilities, sanitary and break areas, and waste management concepts, as well as the setup and supervision of installation activities in close coordination with Körber’s project management team and the external trades.
Space & Logistics Management:
Coordination, scheduling and strategic allocation of pre-assembly areas, as well as precise management of all construction-site deliveries.
Cross-Trade Coordination:
Interface management and operational coordination between the various construction, installation management and commissioning teams from different third-party providers.
Installation & Commissioning Supervision:
Continuous planning, supervision and monitoring of all mechanical, electrical and IT-related installation activities, including close support during commissioning, partial acceptance and final acceptance.
Quality Assurance & Documentation:
Complete documentation of all activities in the construction diary, recording of potential construction defects and strict coordination of their rectification.
Schedule & Safety Controlling:
Ongoing schedule planning, regular construction meetings and progress reporting in coordination with Körber, as well as continuous monitoring of compliance with safety and health regulations in consultation with the construction safety coordination team under the BauKG.

Project Success in Figures

Thanks to the close integration of all project stakeholders and MONTECO’s tightly organized installation activities, the ambitious milestones set by the end customer were not only met, but even optimized:

Project Metric / Target

Result & Project Success

This project clearly demonstrates that even under the most challenging conditions during ongoing operations, MONTECO ensures smooth, structured and safe processes on major construction sites. We would like to thank Körber Supply Chain Automation GmbH for the trust placed in us and Greiner Bio-One GmbH for the excellent cooperation on site.