With a brand-new lineup of electric vehicles (EVs) set for production, this prestigious client sought a strategic partner to transform their Southeastern manufacturing plant.
The fully operational facility, a six-million sq ft site, was being upgraded to facilitate and streamline EV production. At Gleeds, we provided a suite of project management services, including several operational and technological upgrades amidst live production.
The programme included more than 20 projects of varying sizes, stretched across 780,000 sq ft. The schedule of works included developing two new buildings within the paint shop. The first was a 45,000 sq ft facility devoted to sound attenuation, and the second, an 8,000 sq ft building intended to house a new painting technology. Modern robotics, innovative power distribution systems, updated conveyors, and new loading docks were introduced into the body shop. The assembly shop was also an area of focus, with renovations mandated to support a new conveyor system.
The challenge
The construction of a new programme in a working facility, with specific goals and consumer demands, posed a significant challenge. These included the site’s scale, the collective push to expedite production, alongside liaising with the key stakeholders ongoing. With the site remaining fully operational throughout, the biggest obstacle for Gleeds to overcome was the live operations and challenges around communication, health and safety, scheduling, and the integration of technology.
Solutions
By adopting a strategic approach in all key phases, we reduced the potential for costly disruption for the client. For example, we introduced careful scheduling and clear communication between stakeholders and seamlessly integrated new technologies into the existing facility. Our Atlanta team was quick to identify and integrate effective mitigation strategies, including:
- Strategic scheduling for construction around live operations: tasks were spread across weekends, nights and planned plant shutdown periods with work scheduled and approved far ahead of time to minimise disruption and simplify wider planning. This strategic approach to scheduling helped both new and existing operations run concurrently.
- Open communication with stakeholders: a flexible schedule with clear goals, capturing all stakeholder perspectives, helped operations run smoothly and achieve client objectives.
- Developing a centralised meeting platform to combat the geographical diversity of teams. Our central platform streamlined approvals and communication across global teams. By involving end-users early, we minimised change orders and drove collaboration across diverse teams.
- In-house expertise for technology integration: enhancing older systems while integrating new ones proved challenging. Our team successfully leveraged our in-house expertise to fill gaps and improve reporting.
Results
Our team generated a 5% cost saving and a 15% schedule improvement, contributing to the overall success of this EV rollout. Strict project management and strategic planning supported the client in meeting critical milestones and, crucially, upholding recognised global standards.
Through strict monitoring of quality margins and technical standards, we also succeeded in keeping the production running smoothly and were able to mitigate any compromises to future manufacturing.
