Case Study Design Build Line

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Woodard & Curran Design-Build Manufacturing Line

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Case Study Design Build Line

  1. 1. Case StudyDesign – Build Line
  2. 2. The Client Facilities have stagnated and not kept pace with the industry New manufacturing upgrades were needed to update technology and build a competitive manufacturing advantage Need to “start from scratch” to upgrade existing plants
  3. 3. The Project $20+ million manufacturing line expansion Covered all engineering disciplines  Packaging  Utility Infrastructure  Electrical and controls  Building modifications
  4. 4. Contracting Methodology Design – Build  Owner purchased packaging equipment  W&C purchased/installation/commissioning utility equipment  W&C line installation and commissioning Shared Risk Model  Guaranteed line performance with bonus/penalty  Cost plus with shared savings  Guaranteed maximum price with owner held contingency
  5. 5. Phase 1 - Design Basis and Cost Estimation Preliminary engineering study Developed scope, schedule and budget in conjunction with client Worked with a variety of resources including suppliers, client and previous experience
  6. 6. Phase 2 - Packaging Equipment Selection Developed packaging specifications  Blow molding  Filler/Capper/Labeler  Case Packing  Palletizing Bid to equipment suppliers Evaluated supplier bids and provided client recommendations Lead final negotiations in partnership with client
  7. 7. Phase 3 – Line Layout Needed to make sure client desired equipment fit in the space provided Design considerations:  Decoupling of equipment zones  Material flow and storage  Manning  Future expansion
  8. 8. Phase 4 – Support Infrastructure Design and Procurement Review and upgrade systems  Compressed air  Cooling water  Chill water  Electrical Power  Control Systems Procured all equipment
  9. 9. Phase 5 – Packaging Equipment Reviews Review equipment being provided by suppliers  30 % review (order acknowledgement and specifications conformance)  60% review detailed review of subsystems  Factory acceptance testing
  10. 10. Phase 6 – Contractor Selection Pre-qualify contractors based upon  Safety record  Financial Stability  F&B Experience Develop bid packages for contractors Obtain and analyze bids Finalize contractor selection
  11. 11. Phase 7 – Installation W&C was responsible for all construction management on-site  On-site construction manager  Fiscal responsibility for all contractors  Initial safety training  Daily coordination meeting  Maintained a project file system (Buzzsaw)  Monthly client-W&C team meeting  Managed overall construction schedule  Safety audits by corporate safety manager
  12. 12. Phase 8 – Commissioning Responsible for all equipment commissioning  Managed and fiscally responsible for equipment vendors  Managed equipment cleaning processes prior to startup  W&C engineers on-site testing and documenting startup  Equipment centers tested individually and as system  Completed punch lists
  13. 13. Phase 9 - Closeout W&C Completed a Project Closeout  Compiled all equipment manuals  Coordinated vendor training  Completed packaging vendor closeouts  Provided client a detailed asset cost basis summary  Completed a lessons learned presentation
  14. 14. The Results All equipment centers passed 95% or more efficiency Overall line achieved greater than 98% efficiency – achieved line performance bonus Completed within budget (included some owner held contingency) Completed on schedule Celebrated successful line startup with a ribbon cutting ceremony including W&C CEO.

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