INDUSTRY: Primary Metals SERVICES: Business & Operations Consulting – Engineering Feasibility Study
ABOUT THE CLIENT
EAD met the needs of a leader in the design and fabrication of modular buildings and specialized modular structures. The steel manufacturer serves the industrial, defense, and residential markets with several brand-name product lines and is committed to long-term investment in opportunities for driving growth, improving operational efficiencies, and creating a safer, more ergonomically sound work environment.
PROBLEM TO SOLVE
Our client’s rapid product and operational diversification and growth outpaced the capacity and layout of their existing campus. The space limitations of their existing facility led to multiple operational inefficiencies: Material handling had become cumbersome and required excessive internal transport; the cramped layout impeded personnel safety, productivity, and operational workflows; and production requirements could not be met. In addition, bottlenecks in the blasting, painting, and fit-out areas and the use of non-standard components made it difficult to meet production increases. Our client requested the expertise of EAD to help consolidate their operation under one roof. Through a feasibility study, EAD helped our client understand the requirements of their space, recommend technology and efficiency improvements, and develop an estimated ROI for the proposed investment.
APPROACH & SOLUTION
In partnership with a local construction firm, EAD facilitated six “visioning sessions” with the key client stakeholders and their specialty consultants to assess the feasibility and ROI of the proposed expansion. Through these collaborative workshops, EAD and the stakeholder team developed a phased site and building plan that facilitated long-term scalability. The plan included an in-depth map of the facility process workflow (from raw materials processing to final fit-out). It also identified existing bottlenecks and pain points, and it analyzed ways to best incorporate LEAN manufacturing principles within the design to improve the facility layout and process flows. The project team evaluated the welding, blasting, painting, and materials transport operations for opportunities to improve site ergonomics and implement automation.
Utilizing Bluebeam, Revit, and in-field observation, EAD was able to co-create a vision aligned with our client’s goals. We provided the following deliverables:
- Facility layouts for the initial project phases
- Automation integration plans (robotic welding, jig/fixture design, AVG/MVG material handling)
- Throughput models based on estimated task cycle times and production head-count
- Requirements for the MEP infrastructure
- Budget-level cost estimates and a project phasing strategy
- Equipment lists and high-level specifications
RESULT & BENEFIT
EAD developed a Phase I facility concept for our client’s expansion, consolidating their steel manufacturing operation within a 280’ x 460’ building fabrication using dual high-capacity lines linked to their existing sandblast infrastructure. As part of the feasibility assessment for the phase I concept, we developed a phased capital cost plan with cost options for the initial construction, paint additions, and storage facility enhancements.
Within the final assessment report deliverable, EAD offered recommendations that could be implemented immediately to increase productivity and eliminate process bottlenecks. Our workflow optimization recommendations identified best practices for improving material and product flows to minimize handling and queuing processes. Options were suggested for fit-out and paint improvements for curing booths, blast media reclaim, ergonomic insulation zones, and additional staging. We even assessed our client’s automation readiness, providing a clear road map for introducing semi-automated raw materials retrieval and cutting steps, flexible robotic welding, and plug-and-play utility carts to improve operational efficiencies. By project completion, EAD delivered a scalable, actionable facility and process development concept plan and ROI that successfully aligned our client’s space, labor, and automation investments with their long-term strategic goals.