Facility Condition Assessment (FCA) – Survey of the existing facility to identify all the deferred maintenance items as well as upgrades needed to bring the building into conformance with current SQF, Life-Safety, and ADA codes. We also agreed to look at energy-reduction retrofits that could realize a payback of fewer than five years.
Brainstorming – Meet with all the department managers within the plant to identify all the facility projects required to meet upcoming production, quality, and employee welfare requirements. Special emphasis would be placed on prioritizing renovations necessary to minimize the risk of plant shutdowns due to equipment failures or safety incidents.
Draft Facility Plan – Develop rough scopes and budgets for each of the identified projects. Ultimately, several projects were combined while others were separated into multiple phases. Some projects had to be split into study and implementation phases, as the solution was not readily-apparent and budget projections could range widely until a better investigation of existing conditions and possible solutions were completed.
Finalize Facility Plan – Part of the response to the plan by the occupant managers was to set aside about a third of the projects whose payback period would go beyond Year 5. These projects would be reconsidered if the long-term decision was to renovate the existing building rather than build a new one. Some projects were added, including those that had longer paybacks because they would be needed whether the facility continued as a manufacturing site or was converted to house warehousing and offices.