Case StudyCase StudyDesignDesign –– Build LineBuild Line

The ClientThe Client

Facilities have stagnated and not kept pace withFacilities have stagnated and not kept pace withthe industrythe industry

New manufacturing upgrades were needed toNew manufacturing upgrades were needed toupdate technology and build a competitiveupdate technology and build a competitivemanufacturing advantagemanufacturing advantage

Need toNeed to ““start from scratchstart from scratch”” to upgrade existingto upgrade existingplantsplants

The ProjectThe Project

$20+ million manufacturing line expansion$20+ million manufacturing line expansion

Covered all engineering disciplinesCovered all engineering disciplines

PackagingPackaging

Utility InfrastructureUtility Infrastructure

Electrical and controlsElectrical and controls

Building modificationsBuilding modifications

Contracting MethodologyContracting Methodology

DesignDesign –– BuildBuild Owner purchased packaging equipmentOwner purchased packaging equipment

W&C purchased/installation/commissioning utilityW&C purchased/installation/commissioning utilityequipmentequipment

W&C line installation and commissioningW&C line installation and commissioning

Shared Risk ModelShared Risk Model Guaranteed line performance with bonus/penaltyGuaranteed line performance with bonus/penalty

Cost plus with shared savingsCost plus with shared savings

Guaranteed maximum price with owner heldGuaranteed maximum price with owner heldcontingencycontingency

Phase 1Phase 1 -- Design Basis and CostDesign Basis and CostEstimationEstimation

Preliminary engineeringPreliminary engineeringstudystudy

Developed scope,Developed scope,

schedule and budget inschedule and budget inconjunction with clientconjunction with client

Worked with a variety ofWorked with a variety ofresources includingresources includingsuppliers, client andsuppliers, client andprevious experienceprevious experience

Phase 2Phase 2 -- Packaging EquipmentPackaging EquipmentSelectionSelection

Developed packaging specificationsDeveloped packaging specifications Blow moldingBlow molding

Filler/Capper/LabelerFiller/Capper/Labeler

Case PackingCase Packing

PalletizingPalletizing

Bid to equipment suppliersBid to equipment suppliers

Evaluated supplier bids and provided clientEvaluated supplier bids and provided clientrecommendationsrecommendations

Lead final negotiations in partnership with clientLead final negotiations in partnership with client

Phase 3Phase 3 –– Line LayoutLine Layout

Needed to make sureNeeded to make sureclient desired equipmentclient desired equipmentfit in the space providedfit in the space provided

Design considerations:Design considerations:

Decoupling of equipmentDecoupling of equipmentzoneszones

Material flow and storageMaterial flow and storage

ManningManning

Future expansionFuture expansion

Phase 4Phase 4 –– Support InfrastructureSupport InfrastructureDesign and ProcurementDesign and Procurement

Review and upgradeReview and upgradesystemssystems

Compressed airCompressed air

Cooling waterCooling water

Chill waterChill water

Electrical PowerElectrical Power

Control SystemsControl Systems

Procured all equipmentProcured all equipment

Phase 5Phase 5 –– Packaging EquipmentPackaging EquipmentReviewsReviews

Review equipment being provided by suppliersReview equipment being provided by suppliers

30 % review (order acknowledgement and30 % review (order acknowledgement andspecifications conformance)specifications conformance)

60% review detailed review of subsystems60% review detailed review of subsystems

Factory acceptance testingFactory acceptance testing

Phase 6Phase 6 –– Contractor SelectionContractor Selection

PrePre--qualify contractors based uponqualify contractors based upon

Safety recordSafety record

Financial StabilityFinancial Stability

F&B ExperienceF&B Experience

Develop bid packages for contractorsDevelop bid packages for contractors

Obtain and analyze bidsObtain and analyze bids

Finalize contractor selectionFinalize contractor selection

Phase 7Phase 7 –– InstallationInstallation

W&C was responsible for allW&C was responsible for allconstruction management onconstruction management on--sitesite OnOn--site construction managersite construction manager

Fiscal responsibility for allFiscal responsibility for allcontractorscontractors

Initial safety trainingInitial safety training

Daily coordination meetingDaily coordination meeting

Maintained a project file systemMaintained a project file system(Buzzsaw)(Buzzsaw)

Monthly clientMonthly client--W&C teamW&C teammeetingmeeting

Managed overall constructionManaged overall constructionscheduleschedule

Safety audits by corporate safetySafety audits by corporate safetymanagermanager

Phase 8Phase 8 –– CommissioningCommissioning

Responsible for allResponsible for allequipment commissioningequipment commissioning

Managed and fiscallyManaged and fiscallyresponsible for equipmentresponsible for equipmentvendorsvendors

Managed equipment cleaningManaged equipment cleaningprocesses prior to startupprocesses prior to startup

W&C engineers onW&C engineers on--site testingsite testingand documenting startupand documenting startup

Equipment centers testedEquipment centers testedindividually and as systemindividually and as system

Completed punch listsCompleted punch lists

Phase 9Phase 9 -- CloseoutCloseout

W&C Completed a Project CloseoutW&C Completed a Project Closeout

Compiled all equipment manualsCompiled all equipment manuals

Coordinated vendor trainingCoordinated vendor training

Completed packaging vendor closeoutsCompleted packaging vendor closeouts

Provided client a detailed asset cost basis summaryProvided client a detailed asset cost basis summary

Completed a lessons learned presentationCompleted a lessons learned presentation

The ResultsThe Results

All equipment centers passed 95% or moreAll equipment centers passed 95% or moreefficiencyefficiency

Overall line achieved greater than 98%Overall line achieved greater than 98%efficiencyefficiency –– achieved line performance bonusachieved line performance bonus

Completed within budget (included some ownerCompleted within budget (included some ownerheld contingency)held contingency)

Completed on scheduleCompleted on schedule

Celebrated successful line startup with a ribbonCelebrated successful line startup with a ribboncutting ceremony including W&C CEO.cutting ceremony including W&C CEO.