Our team helped the client understand and improve its current operations, develop a detailed expansion plan, and prepare for future growth.
The Challenge
A leading U.S. paint and coatings manufacturer was nearing capacity for a key production process at two of its domestic facilities. Company management sought clarity regarding the best path forward, whether through the expansion of one of the existing plants or via a new facility.
They turned to ChemQuest for a thorough analysis of their operations, including: a review of the existing plants, processes, and capabilities; forecasted growth; and future expansion potential.
Thorough Operational Review and Project Management
This multi-faceted project encompassed several key focus areas: plant review, process optimization, and site design.
Plant
Review
- Analyzed existing manufacturing operations
- Identified limitations and uncovered potential synergies between the two plants
Process
Optimization
- Analyzed processes such as supply chain (inbound and outbound, including warehouse requirements), R&D, QC testing, filling, and packaging
- Analyzed manufacturing processes and equipment, including safety and occupancy requirements
- Evaluated the selection of potential new equipment
- Benchmarked efficiency and identified opportunities for efficiency gains
Site
Design
- Served as Project Manager for the facility designs
- Worked with an engineering firm to ensure optimal building and plant layouts
The Results
The ChemQuest team provided detailed analysis and input on process optimization priorities, plant site and layout, and CapEx where needed. Our experts informed and guided the design of facilities that met the company’s current needs and will provide ample capacity for future growth as needed. The client utilized our thorough demand forecast to develop a five-year plan that will help guide them to success in the future.