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Rationalisation / Optimisation of Manufacturing Sites

Using visualisation techniques and 3D drawings to produce master planning documents that enabled the manufacturing firm to produce a business case for rationalising manufacturing sites

Multiple plants of a manufacturing firm requiring rationalisation

A large manufacturer of plastic products had over the years been focused on engineering quality assurance. Following a market crash which triggered a slump in construction activity, this business’s European operations considered consolidation/ rationalisation of its manufacturing plants and focusing on lean manufacturing to optimise manufacturing operations. The business required a site development strategy for their Irish site.

Master planning document for manufacturing site optimisation

Malone Group was engaged by the customer for this master planning project. It involved not only architectural and design skills but also operational expertise. The building layouts, flow of vehicles and personnel were analysed to assess the impact of changes to the site in the context of the surrounding areas and buildings. The aim was to layout the site such that the core hub/pivot point of the site had to have the shortest distance between all buildings. Given the scale and size of the site, this challenge required an innovative approach.

We developed a masterplan involving new facilities through spatial planning, allowing for people and vehicle movements and safety between vehicles and pedestrians on the site. We also produced development plans which had to be sensitive to the zoning of the site and surrounding areas, which included adjacent residential areas. There were several legacy buildings and utilities services on site with underground connectivity that needed to be taken into account while developing the masterplan.

Informed decision on the multi-million euro investment of rationalisation project

We produced a series of drawings, including 3D drawings to enable key stakeholders to visualise the plan. We identified key risk areas and provided a complete picture of the potential for the site. The master planning documents that we produced enabled the project stakeholders to sell the business case for rationalisation/ optimisation to the board and make informed decisions on what would ultimately be a multi-million euro investment in the Irish site.