Challenge/Solution Case Study:

Reorganizing Large Manufacturing Complex to Meet Merger Requirements

Result

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.

Challenge

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.

Solution

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.

Deliverables

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

We hired EFI Group to help us figure out a project and scope it, and I felt confident they would keep a keen eye on it. They had to deliver quickly and they did it well. They are especially good at project management when you don’t have the resources to do it internally. Reliability is the word I would use to describe EFI Group.
— Coatings Industry Professional
EFI Group is timely. We’ve had a lot of situations when we’ve been in a time crunch and they’ve responded very quickly. They are detail oriented and efficient. They’re a good group of people who also have a lot of strength in pre-engineering — the thought process to get to preliminary design and making sure we’ve investigated all the potential asks of a project to ensure we didn’t miss anything. They have great attention to detail up front which is very important to any project because having that detail-oriented deep dive into the pre-engineering phase sets the stage for the success of the rest of the project, making the process smoother and making it much easier to keep the project on schedule and on budget.
— Mike Quigley, Engineering & Maintenance Manager, Food Industry
I’ve worked with EFI Group for a while, so I know they have a good, knowledgeable staff. We know we’re going to get the results from them we expect. From my interactions with all the different EFI team members I’ve worked with, I know they have knowledge across many industries. Equally, I never have to follow up with EFI Group and, in some cases, they keep me on track.
— Ryan Fredsall, General Manager, Pacer Minerals LLC
We view EFI Group as a team that can dimensionalize our capability to execute projects. We can articulate what it is we want to do and they can take that input and run with it without much intervention from us. They’re able to move a project along independently and only engage us when it’s time to bring us up to speed or get more input to drive a project to conclusion. That’s one of the reasons I view them as an excellent contractor.
— Environmental Engineering Industry Professional
EFI Group has good engineers and good customer service. We know when we get an EFI engineer on a project, we’re going to a get a good job from them and it’s been a productive relationship for both of us — I genuinely like the people.
— Corporate Director, Project Management in Food & Flavors Industry
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