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Factory Capacity and Reliability Upgrades Project

This project consisted of capacity upgrades to existing clean manufacturing campus to support new manufacturing processes, replacement of aging equipment to increase reliability, seismic upgrades and other owner maintenance work to enhance the performance of the campus. The work included extensive mechanical and electrical system upgrades, including the installation of new make-up air handling units, new general and corrosive exhaust systems, RUPS Power system, boilers, cooling towers, and chillers, and various waste systems to support the new manufacturing processes. The project team was assembled to address existing challenges with safety culture, quality, and consistency of delivery. The team utilized proven delivery models from similar projects while adapting processes to existing conditions. Lean principles were used throughout, starting with weekly workgroups comprised of owner stakeholders, designers, builders, and key trade partners working together to develop the design to standing weekly meetings and check-ins to evaluate indicators and team health. The Last Planner System was used in full, including Pull Planning, weekly work plans, and daily stand-ups to drive efficiency and accountability in the scheduled work. Opportunities for continuous improvement and innovations were reinforced throughout the project, resulting in a reduction in the overall project cost and delivering the project systems on time to meet tool installation and process needs.