Success Story: How FILL optimized assembly space planning with AREAPLAN

Forward-looking planning for complex machine assembly

Special-purpose machine manufacturer FILL selected AREAPLAN to bring clarity and efficiency to its assembly space planning. The solution is built on Visual Components, the leading 3D simulation platform for robotic simulation, material flow, and plant layout planning. AREAPLAN supports precise scheduling and capacity planning for on-site assembly of complex machinery. It enables significantly better utilization of available floor space – allowing FILL to manage both spatial and temporal resources efficiently across a total of 30,000 m² of production area.

Key Facts at a Glance

Initial Situation & Motivation

• Assembly of very large machines in FILL’s own production halls
• Constantly changing assembly projects
• Hall planning done manually using 1:100 scale cut-out layouts on a pinboard
• Overlapping project timelines made the system hard to manage
• Urgent need for a digital solution – but no suitable tool available on the market

Special Requirements

• Solution had to be based on Visual Components functionality
• Implementation completed in just two months, running in parallel with the existing pinboard method
• Most project meetings and training sessions conducted via remote conferencing

Key Benefits of AREAPLAN at FILL

• Optimal utilization of assembly space
• Accurate delivery time forecasting
• Increased throughput on the production floor

FILL, a global leader in special machine and plant engineering, faced a familiar challenge: how to efficiently plan and manage the assembly of large, complex systems within limited factory space. With constantly shifting project timelines and overlapping space requirements, traditional planning methods were no longer up to the task.

That’s when FILL turned to AREAPLAN, a digital space planning solution developed in collaboration with DUALIS and based on the powerful 3D simulation platform Visual Components.

The initial situation: Manual planning with major limitations

Before 2018, FILL relied on a physical pinboard to plan hall occupancy. Cut-out 2D layouts (scale 1:100) were manually labeled and pinned to simulate project timelines – often stacked on top of each other. This made it nearly impossible to maintain a clear overview.

“The system was difficult to manage. Projects were stacked to simulate time, and the fact that anyone could rearrange them didn’t help,” explains Günther Redhammer, COO at FILL.

Despite an urgent need for a software solution, no existing tool on the market could meet FILL’s dynamic and complex requirements.

The Solution: AREAPLAN – built for real-world complexity

FILL and DUALIS joined forces to develop a tailored solution. The result was AREAPLAN, a digital tool that enables:

• Efficient allocation of assembly space
• Visualization of spatial and temporal planning
• Management of all project-relevant data
• Avoidance of planning conflicts and bottlenecks

The implementation was completed in just two months – running in parallel with the existing pinboard method. Most project meetings and training sessions were conducted remotely, thanks to FILL’s long-standing experience with Visual Components.

Key Benefits at a Glance

• Optimal use of 30,000 m² of assembly space
• Reliable delivery time forecasting
• Increased throughput on the production floor
• Full transparency for all stakeholders
• Scalable and future-ready solution

FILL now uses a high-performance workstation with a dedicated graphics card to run AREAPLAN, displaying results on an 85-inch screen in the production area for maximum visibility.

“Transparency is a major strength. The timeline lets us view upcoming projects at any time. Delays are immediately visible thanks to color coding. Our delivery estimates are now much more reliable and data-driven,” adds Günther Redhammer.

Looking ahead: ERP integration and smart logistics

FILL is planning to integrate AREAPLAN with its ERP system to automatically transfer project data into the planning environment. This will eliminate manual data entry and streamline workflows. The company also plans to use this data to coordinate the delivery of tools and materials directly to the assembly site.

Conclusion: From manual chaos to digital clarity

With AREAPLAN, FILL has transformed its hall planning process – moving from a manual, error-prone system to a transparent, efficient, and scalable solution. The collaboration with DUALIS has proven to be a strategic advantage, combining simulation expertise with real-world manufacturing needs.

Want to Get More Out of Your Assembly or Production Space?

Contact us for a no-obligation consultation – or request your personal live demo. We’ll be happy to tailor the experience to your specific needs.