Challenge/Solution Case Study: Reorganizing Large Manufacturing Complex to Meet Merger Requirements

Nestor Rentas Challenge/Solution Case Studies


EFI Group provided the engineering and project management support to reorganize a large complex production facility within a compressed timeframe. The combination of EFI Group’s technical and manufacturing operations knowledge, coupled with exceptional project management skills, resulted in a successful reorganization, completed within the $2.5 million budget.


The client was purchased by a large multi-national corporation, and was reorganizing production operations to prepare for their future role within the new organization.

The client’s primary production operation is high-tolerance machining of large metal castings. The equipment use and layout had changed considerably over the years, and further changes were anticipated.

As a result, the overall layout of the equipment was no longer optimum, and a large number of machines were now obsolete.

The company’s objective was to relocate and reorganize the critical production equipment in an effort to streamline their production processes and maximize efficiencies.

The client is a unionized facility and desired to engage the employees in this action.

EFI Group was asked to facilitate and manage the relocation and complete the effort within 12 months to coincide with corporate purchasing accounting rules.


In the initial phase, EFI Group established which equipment would be relocated and identified a target plant location of approximately 125,000 SF.

EFI Group facilitated a series of meetings with a client-directed team to prepare a layout for the new production area and provided direction and guidance to insure an effective cell and production flow for the new area.

Once the layout was prepared and approved, EFI Group obtained costs for preparing 36 machine foundations, as well as the rigging and relocation of 73 machines.

Relocation tasks included: moving individual machines and integrated machining centers, coordinating with used equipment brokers to dispose of the obsolete equipment, and clearing the original site.

EFI Group also facilitated the design and construction of required building modifications, organized non-equipment relocation requirements and coordinated relocation without an adverse effect on the customer’s ongoing deliveries.

EFI Group provided support to the client’s budget and performance-tracking efforts via daily contractor review meetings, weekly client updates and ongoing resolution of construction and operational issues.


The relocation was completed within the 12-month requirement with no adverse effect on customer deliveries. EFI Group delivered:

  • Effective equipment layout with agreement from all levels within the organization.
  • Detailed machine foundation design.
  • Detailed design and coordination of the building modifications.
  • Logistical support and direction to accomplish the equipment relocation.

Read more about EFI Group’s Core Competencies
Read additional EFI Group Case Studies