TOP 3 BLIND SPOTS

IN MANUFACTURING EXPANSION FACILITIES

As a manufacturing facility owner, expanding your operations can be an exciting yet challenging endeavor. At EXXCEL Project Management, we've seen countless expansion projects over our 30+ years in the design-build industry. Here are three critical blind spots you need to be aware of to ensure your expansion project's success.

1. Underestimating the Complexity of Integration

When expanding your manufacturing facility, it's easy to overlook the challenges of integrating new spaces with existing ones. Multiple building additions over time can create a hodgepodge of work areas that limit productivity and capacity.

Case Study: ODM Tool & Manufacturing

ODM Tool & Manufacturing in McCook, Illinois, faced this exact issue. After years of expansions, they struggled to incorporate a new 1,200-ton metal stamping press into their workflow. The varying construction methods and ceiling heights of previous additions made it nearly impossible to configure the new equipment effectively.

To avoid this blind spot:

• Conduct a thorough assessment of your current facility layout

• Consider how new additions will integrate with existing spaces

• Work with experienced design-build professionals who can optimize your expansion plan

2. Overlooking the Impact on Ongoing Operations

Many facility owners underestimate the potential disruption an expansion project can have on their day-to-day operations. Prolonged shutdowns to accommodate construction crews can be detrimental to your production schedules and bottom line.

Case Study: Phased Construction Approach

At EXXCEL, we helped a client overcome this challenge by implementing a phased construction approach. By carefully scheduling construction activities, we minimized disruption and allowed the client to remain operational throughout the expansion process. This strategy ensured they met all production deadlines while still achieving their expansion goals.

To mitigate operational disruptions:

• Develop a detailed phasing plan with your design-build team

• Communicate clearly with all stakeholders about construction timelines

• Consider temporary solutions to maintain productivity during construction

3. Neglecting Future-Proofing and Flexibility

In the rush to address immediate capacity needs, it's easy to overlook long-term flexibility and scalability. A short-sighted expansion can lead to limitations down the road, potentially requiring costly renovations or relocations.

Case Study: Flexible Design Implementation

One of our clients in the food processing industry initially planned a modest expansion to accommodate new equipment. By working closely with our team, they realized the potential for future growth and opted for a more flexible design. This foresight allowed them to easily incorporate additional production lines two years later without major renovations.

To future-proof your expansion:

• Consider modular or adaptable design elements

• Plan for potential technological advancements in your industry

• Leave room for growth in utilities and infrastructure

By being aware of these blind spots, you can approach your manufacturing facility expansion with confidence. At EXXCEL Project Management, we specialize in helping clients navigate these challenges, ensuring that your expansion not only meets your current needs but also positions you for future success.

Remember, a successful expansion is about more than just adding square footage. It's about creating a space that enhances productivity, accommodates growth, and adapts to your evolving business needs. Partner with experienced professionals who can guide you through the process and help you avoid these common pitfalls.

Ready to expand your manufacturing facility without the headaches? Contact EXXCEL Project Management today, and let's build your future together.