Ammunition Factory Expansion
Client: Confidential
Summary
We assisted with an ammunition factory expansion. The project integrated multiple pieces of equipment into a lean new manufacturing facility. The Lean Six Sigma consultants worked with the design team and facility operators to develop a cohesive manufacturing line that took into consideration manpower requirements, process flow, material and people movement, as well as the inputs and outputs for each component. Once the process was developed, the building was designed to fit that process, culminating in a lean, efficient facility. A simulation model was used to validate the design of the process and the functionality of the building. The result was a 72,000-square-foot facility that includes mechanical, electrical and maintenance rooms, communications systems, administrative offices and exterior improvements.
The final result was a 72,000-square-foot-facility that is designed to be flexible as the client's business grows and advances. The facility was designed with open column bays, buss ducts and overhead utilities to allow machine and operational flexibility. In addition, the facility includes multiple manufacturing cells; support spaces including powder delivery rooms, mechanical and compressor rooms, maintenance/tool rooms and administrative offices; and exterior improvements.
Services
- Lean Six Sigma analysis
- Design
- Construction services
- Startup
Background
The GMP contract was issued in mid-December 2013. Within four months, our team executed a fast-track schedule to erect the 72,000 -square-foot pre-engineered metal building on approximately 8,000 yards of slab on grade and installed. The building is constructed as a textured block wall on the exterior up to 8 feet, then transitions to metal wall paneling to appeal to the aesthetics of the grounds.
One of the biggest challenges on the project was the weather, which caused delays with more than a month of work-restricting weather from ice storms to unrelenting rain, snow and high winds. We had zero recordables on the project while averaging 8,000 man-hours per month during peak hours.
