Timo Reulein

Project Manager Industrial Drive Solutions

Tel.: +49 (911) 4504 1801

Bühler Motor GmbH


November, 2020

Modern Production –

State of the art

Sometimes, as a project manager in the Industrial segment, I envy my colleagues from the Automotive segment. Not necessarily when it comes to their tight schedules or price pressures, but what I find enviable are the detailed specifications of products and, from an industrial perspective, the enormous production volumes their projects represent.

The challenge we face in the Industrial Drive Solution segment is the tremendous variance of requirements within any given motor size, a variance that depends on the industry and installation space. So, we have tremendous variance at moderate to small production volumes, but – like in Automotive – we must manufacture to the highest quality standards. The answer we have found to this challenge is a flexible, modular toolkit, which is based on the principle of creating many different components and add-on parts early in the basic mechanical design of the motor family. The modular toolkit builds upon different noise suppression variants, different wire gages, predefined shaft lengths, optional temperature sensors, and much more. The option of installing alternative components is guaranteed by uniformly defined interfaces and mounting points both inside and outside the motors.

State of the Art Production at Bühler Motor in Monheim, Germany.

We continue to test these modular parts in various combinations to create a broad-based standard. The large number of validated variation options that have resulted already allows us to fulfill many customer wishes and different specification requirements. If a special shaft end or a specific wire harness is needed in our layout and testing work, we just focus on the differences and special validation tests that need to be performed. The product is standardized wherever possible and customer-specific wherever necessary.

„But this flexible design approach is not really effective until it is matched with optimal order processing and production control.“

Timo Reulein

But this flexible design approach is not really effective until it is matched with optimal order processing and production control. The modular parts named above are stored in a logical structure in our quotation and ordering systems together with the necessary combinations. This makes preselection possible, and in the consulting process we can already determine whether we can utilize an existing combination of products or whether we need to initiate an ‘engineering variant’. As soon as the motor type is configured in the system, or an order is received for it, the material availability is assured, and the production order is initiated. Program and configuration parameters are also defined for the lines. The manufacturing execution system (MES) is used to transfer the order and all necessary information to the line and to ensure that suitable equipment is prepared and the right individual parts are installed. Order feedback on the number of parts produced is also automated.

Bühler Motor has all the procedures and processes …

… you need to take your product to series production.


This allows us to respond quickly and efficiently to the requirements of our industrial customers, because the process flow is logically interconnected – from customer consulting to production. Small lot sizes and variations are welcome in our daily business, because they can be handled by the wide-ranging configuration options offered by the modular toolkit and automation of our production lines.


We look forward to hearing from you!

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