Phase 1 – Facility Master Plans

St. Onge leverages a proven master planning methodology in the optimization and design of existing and new manufacturing operations. The Master Plan provides a “design year” operations road map to optimize manufacturing operations and to ensure the most effective solutions are implemented. Master Planning is driven by statistical data analysis and development of operational design requirements for future state demands and goals. The most effective facility designs consider the total picture and how the manufacturing facility fits into the overall supply chain infrastructure. St. Onge resources analyze the system from when trucks enter the site until the trucks leave the site including all operations in between.  Significant focus is placed on employee, truck, and material movements as well as storage, drop lots, docks, and internal supporting workspaces.  Process flow diagrams and operations documentation form the basis of an inside-out approach to optimize the operation and form the walls around them (not vice-versa).  This master planning methodology also works well for existing facilities that are planned for  expansion or modifications.   St. Onge evaluates flow directions, site access, automation, expansion, and process improvements from manual processes through fully automated design solutions and justify investments compared to an engineered base case solution.

A facility master plan can include the following evaluations, but can also be focused on a specific functional areas:

• Detailed Data Modeling
• Process Improvements
• Space & Layout Planning
• Material Flow Mapping
• Storage & Material Handling Evaluations
• Conventional / Lower Cost Options
• Automation
• Labor Modeling and Productivity Rate Development
• Capital Investment Calculation and ROI
• Technology / Software Evaluations
• Safety, Quality, Flexibility, Expansion
• Simulation Modeling & Analytics

The general approach to providing a facility master plan includes the following:

• Site Visits / Observations
• Data Collection and Modeling
• Base Case Design Solution
• Technology/ Automation Vision Session
• Alternative Design Development
• ROI and Financial Modeling
• Recommendations
• Implementation Strategy
• Next Steps