Click to edit Master title style Planning and Designing a Lean Manufacturing Facility

Click to edit Master title style HISTORY Founded in % employee owned STRENGTH $2.0B sales EPC capability STABILITY Growth during recession < 4% employee turnover SERVICE 85%+ repeat client base Relationship driven business model Our Mission: Make Our Clients Successful Company Profile

Click to edit Master title styleLocations

Click to edit Master title style From start-to-finish, we provide: – Project Development & FEP: Site development Environmental assessment & permitting Utility interconnection Conceptual designs Master planning Technology selection Estimating LEAN | Six Sigma Design – Plant & Site Support Small capital projects Troubleshooting Project support Field engineering Full-Service Execution – Engineer, Procure, & Construct Detailed design Project procurement & expediting Schedule & cost controls Subcontractor sourcing & prequalification Safety & health training Start-up & commissioning

Click to edit Master title style Lean Six Sigma Lean Six Sigma (LSS) has historically been seen as a quality and efficiency tool used on the manufacturing floor Many manufacturing companies have begun to incorporate LSS methodologies into the design/ renovation of their facilities – Reduce Square Footage – Reduce Capital Construction Cost – Increase Efficiency – Optimize People & Product Flow – Leverage New Technologies

Click to edit Master title styleTypical Process How many square feet do we need? How big will the building be? What is our budget to do this project? What utilities are required? Who is going to manage this project? How quick can we get a layout done? Are These the Right Questions??

Click to edit Master title style Design for the Process The Value Stream People Flow Material Flow Material Management Production of Goods Management of Finished Goods Information Management Waste/Dunnage Management

Click to edit Master title style The Design Process Design the Building or Space Around the Process Collect Facility & Process Requirements Select a Site – Cause & Effect Matrix Generate Conceptual Layouts Based on Data Select a Layout and Simulate Phased Design to Meet rate Increases Estimate Cost Build Schedule/Phase Construction

Click to edit Master title style The Design Process – Data Collection Data Collection – Cycle Times – Work Schedules – Rate Demand – Takt Time Create Process Maps – VSM – Swim Lane – Spaghetti Collect Customer Requirements – Financial Requirements – Facility Goals – Quality and Efficiency Targets – Compliance & Permitting

Click to edit Master title style Aerospace Coating Facility Process Teamed with Industrial & Manufacturing Engineers Mapped the Process Improved the Process Flow Generated the Process Layout Integrated new technologies Developed the Building Layout & Initial Design Simulated the Process in the Building Results Reduced Facility Footprint by 20% from Original Concept Developed a Phased Build Plan for Production Reduced Anticipated Capital Spend by 25% Simulation Identified Areas for Improvement

Click to edit Master title style Projectile Manufacturer Process Created Manufacturing Cells Developed Single Piece Flow Generated the Cell Process Layout Integrated Automated Material Handling Developed the Building Layout & Design Simulated the Process Results Reduced Facility Footprint by 10% from Original Concept Determined a Phased Build Plan to Support Increased Production Reduced Cycle Time from 9 Days to 1 Day

Click to edit Master title styleOil & Gas Supplier Process Design Reduced Square footage by 15% Manufacturing Process Design Automated Material Handling Robotic Assembly & Machining Robotic Machine Tending Automated material handling integrated into the manufacturing process

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Chris Williams, MBB, PMP Project Manager Burns & McDonnell