Project Start Date: Sun 8/8/99
Project Finish Date: Mon 4/10/00
| 1 | Start Plant Reconfiguration Project - Construction, Moves and Rearrangements | 100% | ||||
| 2 | Phase I: Project Initiation | 28% | ||||
| 3 | Sponsorship: Define needs and determine expectations for ongoing updates and support. | 60% | ||||
| 1 | IE Hart- Greg | 60% | ||||
| 4 | Resources: Identify project resources, and contacts. Clarify roles and responsibilities. | 40% | ||||
| 1 | IE Hart- Greg | 40% | ||||
| 5 | Project Background: Interview to obtain background on plant expansion project and company. Discuss status, plans, progress and expected results. | 30% | ||||
| 1 | IE Hart- Greg | 30% | ||||
| 6 | Strategies & Assumptions: Identify measurable goals, objectives, case for action, applicable strategies, assumptions, constraints, and criteria. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 7 | Phase II: Plan Macro Layout and Plant Addition. Obtain Approvals. | 13% | ||||
| 8 | Macro Layout Inputs: Review / collect input on macro space needs and department interdependencies – material and communications flow. | 10% | ||||
| 1 | IE Hart- Greg | 10% | ||||
| 9 | Shared Areas: Determine optimum locations for cafeteria, restrooms, corridors and other shared space. | 30% | ||||
| 2 | AR Architect | 30% | ||||
| 1 | IE Hart- Greg | 30% | ||||
| 9 | CL Plant Manager | 30% | ||||
| 10 | CL Operations Manager | 30% | ||||
| 10 | Macro Layout: Prepare macro layout including department / work areas, shared areas, aisles, interior walls and doors. | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | Construction Permits: Obtain approval of town zoning commission and any other necessary agencies to proceed with construction. | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 12 | Phase III: Define Micro Plant Layout | 0% | ||||
| 13 | Resource Identification: Identify department managers and other plant personnel to provide detailed input on layout. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 14 | HR Human Resources Mgr. | 0% | ||||
| 14 | Detailed requirements: Conduct reviews with identified personnel. Identify specific needs. Identify current problem areas and identify improvements. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 10 | CL Operations Manager | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 15 | Dept. Interactions: Clarify and optimize interactions and relationships between departments and support functions. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 16 | Equipment Inventory: Inventory equipment and furniture. Assign individual numbers to facilitate move coordination. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 17 | Equipment Drawings: Measure equipment and furniture footprints and develop CAD templates. Take digital photos. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 18 | Equipment Needs: Identify equipment needs including move special handling and hookup requirements (electrical, exhaust, air, vacuum, water, etc.) | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 19 | Equipment Database: Marry CAD drawing, equipment basics and digital photos in database. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 20 | Flexibility: Design flexibility into the layout including such things as quick release hook-ups, standard services grid, and air pallets. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 21 | Preliminary Micro Layout: Define layout based on input. Prepare CAD layout options for review. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 22 | Preliminary Layout Selection: Evaluate preliminary layout options vs. assumptions, constraints and criteria. Select a layout. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 10 | CL Operations Manager | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 23 | Phase IV: Design Construction and Utilities for Addition | 0% | ||||
| 24 | Construction Design: Design placement of walls and building features such as staircase, cafeteria, locker rooms and bathrooms | 0% | ||||
| 25 | Foundation and Concrete Floor Design Design: Designfootings for construction and concrete floor for new building. | 0% | ||||
| 26 | Floor Coverings: Design and select floor coverings including tiles and carpeting - consider conductive. | 0% | ||||
| 27 | Ceiling treatment: Design drop ceiling - consider non-particulate ceiling tiles. | 0% | ||||
| 28 | Electrical Design: Design electrical grid, buss bar(s), drops and wall plugs. | 0% | ||||
| 29 | Electrical Design: Design electrical grid, buss bar(s), drops and wall plugs. | 0% | ||||
| 30 | HVAC Design: Design HVAC trunk line, branches, vents and machine exhaust | 0% | ||||
| 31 | EPA Approvals: Obtain EPA approvals for roof penetrations and exhaust. | 0% | ||||
| 32 | Plumbing Design: Design water input and drains, plumbing and bathroom fixtures. | 0% | ||||
| 33 | Phase V: Prepare Plan, Bids and Budget for Project | 0% | ||||
| 34 | Project Plan Inputs: Meet with selected contractors and subcontractors. Define activities, timing, resources, information needs and interfaces. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 4 | SC HVAC Subcontractor | 0% | ||||
| 5 | SC Electrical Subcontractor | 0% | ||||
| 6 | SC Plumbing Subcontractor | 0% | ||||
| 7 | SC Carpenters | 0% | ||||
| 8 | SC Drywall Installers | 0% | ||||
| 12 | SC Site Prep Concrete Subcontractor | 0% | ||||
| 35 | Integrated Project Plan: Create an integrated project plan for construction, preparing for occupancy, personnel and equipment moves. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 36 | Bid Approach: Decide approach for bidding - prime contractors with bids to subs, subcontractors assigned to prime contractor, other. | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 37 | Bid Criteria: Bid team of architect, consultant and sponsors provide input on evaluation criteria for contractors – cost, quality, and record of performance. | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 38 | Bid Submission: Prepare and submit bid packages to selected contractors and subcontractors.Select contractors based on estimates and other criteria. | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 39 | Project Budget: Prepare a detailed budget to track project expenditures. Build in contingency for unanticipated developments and changes. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 40 | Start Construction: Break ground. Commence work on addition. | 0% | ||||
| 41 | Project Coordination: Coordinate work of prime contractor and subcontractors.Manage changes. | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 42 | Project Tracking: Track activity completion on project plan. Track expenditures vs. budget. | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 43 | Phase VI: Construct Plant Addition | 0% | ||||
| 44 | Foundation: Excavate and pour foundation for new building. | 0% | ||||
| 12 | SC Site Prep Concrete Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 45 | Exterior Framing: Frame exterior walls and roof trusses for new building. | 0% | ||||
| 7 | SC Carpenters | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 46 | Roofing: Install roof for new building. | 0% | ||||
| 13 | SC Roofers | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 47 | Exterior Walls: Construct exterior walls with panels insulation. | 0% | ||||
| 7 | SC Carpenters | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 48 | Rough Electrical: Rough in electrical grid,exterior wall wiring, boxes and infrastructure | 0% | ||||
| 5 | SC Electrical Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 49 | Rough HVAC: Install HVAC trunk lines and branches. | 0% | ||||
| 4 | SC HVAC Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 50 | Rough Plumbing: Install pipes for water mains and branches. | 0% | ||||
| 6 | SC Plumbing Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 51 | Concrete Floor: Pour and level concrete floor for new building. | 0% | ||||
| 12 | SC Site Prep Concrete Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 52 | Phase VII: Complete Addition Interior Construction | 0% | ||||
| 53 | Interior Walls Framing: Frame interior walls | 0% | ||||
| 7 | SC Carpenters | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 54 | Interior Walls Electrical: Install electrical wiring and boxes in interior walls. | 0% | ||||
| 5 | SC Electrical Subcontractor | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 55 | Interior Walls Finishing: Install insulation and dry wall on interior walls. Tape and sand. | 0% | ||||
| 8 | SC Drywall Installers | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 56 | Painting: Paint walls and trim. | 0% | ||||
| 15 | SC Painters | 0% | ||||
| 3 | PC Prime Contractor | 0% | ||||
| 57 | Bathrooms: Construct bathrooms, partitions, plumbing and fixtures | 0% | ||||
| 58 | Floor Tile: Install tile on floor | 0% | ||||
| 59 | Carpet: Install carpet as required - consider conductive, low pile carpet | 0% | ||||
| 60 | Punch List: Prepare punch list of corrective actions and follow through to ensure completion. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 61 | PhaseVIII: Review and Improve Manufacturing Processes | 0% | ||||
| 62 | Schedule Review: Review process and customer requirements for each product line. Determine takt time, cycle time and capacity vs. load. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 63 | Quality: Obtain data on quality and defects. Define ways to improve quality and reduce defects. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 64 | Process Observation: Observe manufacturing operations to ensure layout incorporates best possible operating methods. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 65 | Process Detail: Prepare videotapes, flow charts, photos and documents to describe current and improved line process. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 66 | Material Flow: Identify optimum material flow and material replenishment paths and methods. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 67 | Cells, Line Balance: Design cells where applicable. Determine optimum line balance – tooling and personnel. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 68 | Final Micro Layout: Define layout based on input. Prepare CAD layout options for review. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 2 | AR Architect | 0% | ||||
| 69 | Final Layout Selection: Evaluate layout options vs. assumptions, constraints and criteria. Select a layout and obtain final approvals. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 9 | CL Plant Manager | 0% | ||||
| 10 | CL Operations Manager | 0% | ||||
| 11 | CL Process Engineer | 0% | ||||
| 70 | Approvals: Obtain necessary approvals such as EPA and upper management. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 71 | Phase IX: Plan Layout Transition | 0% | ||||
| 72 | Move Resources: Identify needed and available resources for moves - riggers, internal personnel, office movers,equipment, etc. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 73 | Production Requirements: Determine production schedule, build-ahead potential and available equipment move windows. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 74 | Move Plan: Create detailed transition plan withequipment numbers, from-to locations, resource needs, work packages and timing. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 75 | Phase X: Move into New Facility | 0% | ||||
| 76 | Move Coordination: Coordinate equipment moves and rearrangements, with close-in planning and supervision. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 77 | Employee Involvement: Involve operators and office personnel in final area setup and process refinement. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 78 | Process Startup: Ensure qualified and timely equipment and process startup. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 79 | Progress Reporting: Monitor and report reconfiguration progress, conformance to schedule and expenditures vs. budget. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 80 | Punch List: Prepare punch list of corrective actions and follow through to ensure completion. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 81 | Phase XI: Construct Building Connection | 0% | ||||
| 82 | Temporary Personnel Location: Relocate personnel as necessary temporarily during the move | 0% | ||||
| 83 | Connecting Area Interior Walls Framing: Frame interior walls for cafeteria, locker room, entranceway and new conference rooms. | 0% | ||||
| 84 | Interior Walls Electrical: Install electrical wiring and boxes in interior walls for cafeteria, locker room, entranceway and new conference rooms. | 0% | ||||
| 85 | Interior Walls Finishing: Install insulation and dry wall on interior walls for cafeteria, locker room, entranceway and new conference rooms. Tape and sand. | 0% | ||||
| 86 | Painting: Paint walls and trim for cafeteria, locker room, entranceway and new conference rooms. | 0% | ||||
| 87 | PhaseXII: Rearrange Exising Facility | 0% | ||||
| 88 | Move Coordination: Coordinate equipment moves and rearrangements, with close-in planning and supervision. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 89 | Employee Involvement: Involve office personnel in final area setup and process refinement. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 90 | Punch List: Prepare punch list of corrective actions and follow through to ensure completion. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 91 | Phase XIII: Follow-up | 0% | ||||
| 92 | Process Opimization: Review and optimize the process to take full advantage of the new layout. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 93 | Coaching: Provide coaching and input to plant supervision, engineering, operators and management. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 94 | Output Verification: Ensure production and product quality levels meet requirements. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 95 | Ongoing: Change Management | 0% | ||||
| 96 | Communications: Develop a communications strategy. Routinely communicate with sponsors and plant personnel. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 97 | Progress Reporting: Report progress and expectations regularly in newsletter, in memos and on bulletin board. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 98 | Problem Mitigation: Provide a sounding board for problems and concerns. Respond promptly and properly. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 99 | Benefits Tracking: Work to ensure process improvements bring expected benefits. Develop and record success measurements. | 0% | ||||
| 1 | IE Hart- Greg | 0% | ||||
| 100 | Work Systems Redesign: Identify impacts to work system including such things as new roles and responsibilities, measures, communication mechanisms, decision rights, incentives and work environment. | 0% | ||||
| 1 | IE Hart- Greg | 0% |