Facility Design Project – 120,000 Sq Ft Food Manufacturing

SITUATION
Large scale food company built a new Manufacturing & Distribution Center and needed support for facility design, equipment selection & process optimization to meet their 3-fold growth forecast.

 PROBLEM
Creating a seamless workflow between 8 departments with various combinations including HACCP environment (ready-to-eat (RTE) and raw), production strategies (just-in-time (JIT) and made-to-stock (MTS)), and inter-departmental product transfers.

 SOLUTION
Lead brainstorming sessions to arrive at a design combining the correct production room interactions & placements with enhanced product flow (from storage to prep to production and packaging), and food-safety-based personnel pathways. Analysis of historical sales and future projections yielded the needed production equipment and room sizing. Process planning sessions were followed by intense UA (user acceptance) testing which ensured functional integration of their ERP and WMS solutions.

 BENEFITS
The new manufacturing facility became a huge success, allowing the company to realize approximately 30% productivity gains. Food Safety was enhanced due to improved product and people flows.  The logical groupings of HACCP zones and production departments improved product transfers.  Additionally, the HVAC design in storage production and chilling capabilities contributed to increased product shelf life.

For more information, contact Michael Stark at 917-397-1837 or [email protected].