Services

Manufacturing Plant Consolidation

CPQP International specializes in manufacturing plant consolidation and distribution facility consolidation. There are several advantages to a consolidation including substantial cost savings by reducing redundant labor, redundant operating systems, operating multiple plants, utilities and housing obsolete equipment, tooling and inventory. When planned efficiently, this is also the perfect time to optimize current processes to operate more efficiently at their new home. A typical consolidation usually consists of one or more plants being moved into a receiving plant.

Our approach:

Consolidation Planning & Due Diligence

planning for a manufacturing plant consolidation includes tasks such as: Determining what plants to shut down and which to keep open, which plant to receive the consolidation, logistical inventory build schedules, what machine moving will be done, costs and savings for transition and negotiations and management of cash and tax incentives.

Receiving Facility Readiness

often times a consolidation will require either substantial upgrades to infrastructure to the receiving plant OR a new facility needs to be established. CPQP handles all infrastructure upgrades to existing facilities and will completely develop a new facility if needed.

Process Optimization

a consolidation is the perfect time to re-engineer the current process lines. CPQP will work closely with the client to develop Lean process cells to be set-up at the receiving facility.

Shut Downs and Moves

once the receiving facility is ready, we will handle all aspects of process line moves including, line shut down, equipment rigging, machine moving, transportation and unloading at the new facility. We will assist the client with shutting down the plant, equipment disposition and clean-up.

Receiving Plant Startup

equipment will be set-up according to the process optimization plan. CPQP will handle all aspects of process line hook-ups to utilities and supervise start-up and ‘first piece’ through. CPQP will also assist in employee training and implementation of quality systems.

Stabilization

stabilization consists of Lean enterprise training, Lean implementation, quality registration, and supply chain migration.

Manufacturing Plant Relocation

There are substantial financial and operating gains to be made when manufacturing plant relocations are well planned and executed. CPQP has developed a specific model when it comes to starting a new plant or relocating an existing plant. Our methodologies are based on our significant experience gained from assisting our clients with over 40 plant startups and relocations worldwide. Typically a plant move includes planning the transportation of plant and material to a new facility and recommissioning while protecting customer sales.

In addition to this method, the CPQP approach uses this prime opportunity to apply Lean methodology to all aspects of the business and uses the move as a window of opportunity to carry out the Lean transformation.

Our approach:

Understanding our Clients

in assisting our clients to meet their objectives, CPQP will come to understand our client’s business model, business culture, management practices, management structure, systems and procedures as well as the back office processes.

Move Planning

the comprehensive move plan must accommodate technology changes, human resources, logistics, move budget and the high level time line. Cross-border moves must also consider import / export brokering, shelter companies, permitting, transportation logistics and distribution.

Preparation

CPQP Lean GAP analysis tool highlights the opportunities for Lean enterprise transformation. This rationalization in turn is incorporated into a new plant layout, plant equipment, sequence of move, sourcing, training plan, systems and defines the finite time line.

Moves and Installations

once the receiving facility is ready, we handle all aspects of process line moves including line shut down, equipment rigging, transportation and unloading at the new facility. Equipment will be set up according to the process optimization plan.

Production Startup

CPQP will handle all aspects of process line integration, including hookup to utilities, supervising start up and ‘first piece’ through. CPQP will also assist in employee training and implementation of quality systems.

Stabilization

Stabilization consists of Lean enterprise training, Lean implementation, quality registration, and supply chain migration