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Facility Design Consulting and Industrial Engineering
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Services
DeHart Consulting
DeHart Consulting is unique among manufacturing management consulting firms in that we use a team-based approach in the vast majority of our assignments. When the client's personnel are brought into the work early and when key client stakeholders are involved with our lean manufacturing consultants the results are measurably successful. While this approach requires an investment of time from the client, it increases overall commitment and a buy-in that pave the way for the successful implementation of the work. This is especially the case in lean manufacturing consulting assignments where the result of the work requires considerable change management.
Successful Engagements
Waymo
Warehouse conversion | San Francisco, CA
Project
Convert former 32,000 sq ft trucking warehouse to fleet tech service garage
Location
San Francisco, California
Project Type
Industrial
Project Size
32,000 sf
Project Duration
18 months
Avison Young and DeHart Consulting partnered to provide construction management and industrial engineering services for Waymo.
32,000 sf warehouse converted to a fleet tech service garage, with:
- 15 service bays, complete with lifts, alignment and balancing machines and exhaust system.
- Service area workstations and work benches, new restrooms and shower, new pantry
- Secure parts and storage cages, with shipping and receiving bay
- 1 interior EV charger
- Office space with conference room, micro kitchen, expanded electrical closet
- Phase 2 involved replacing ADA lift with ADA compliant ramp.
Services
- Facility Design
- Capacity requirements planning
- Traffic flow optimization
Vendor Coordination
- Production Equipment
- Information Technologies
- Architect Interface
Waymo
Warehouse conversion | San Francisco, CA
Project
Convert former 32,000 sq ft trucking warehouse to fleet tech service garage
Location
San Francisco, California
Project Type
Industrial
Project Size
32,000 sf
Project Duration
18 months
Avison Young and DeHart Consulting partnered to provide construction management and industrial engineering services for Waymo.
32,000 sf warehouse converted to a fleet tech service garage, with:
- 15 service bays, complete with lifts, alignment and balancing machines and exhaust system.
- Service area workstations and work benches, new restrooms and shower, new pantry
- Secure parts and storage cages, with shipping and receiving bay
- 1 interior EV charger
- Office space with conference room, micro kitchen, expanded electrical closet
- Phase 2 involved replacing ADA lift with ADA compliant ramp.
Services
- Facility Design
- Capacity requirements planning
- Traffic flow optimization
Vendor Coordination
- Production Equipment
- Information Technologies
- Architect Interface
XILINX, Inc. AsiaPac Headquarters
Manufacturing Facility Design | San Jose, CA | Singapore
Project
Manufacturing, Engineering, & Distribution Center
Location
Changi Business Park, Singapore
Project Type
Industrial
Project Size
290,655 sf
Project Duration
18 months
Xilinx Inc is the leader in programmable logic devices with 50% of the world market share. In the brief to DCI, space efficiency and sustainability was a core design consideration.
The warehouse is designed with automation in mind with direct material handling conduits to the production floor. Smart features such as air flushing, light management system and intelligent environmental features provide a productive working environment.
Tasked to ensure the incorporation of worldwide demand projections to Xilinx’s headquarters, DCI proposed features that enabled a mere 1.1% increase in construction investment but reaps an expected $500,000 savings each year. DCI was responsible for analyzing production rates and capacity to assure that the resulting design was capable of meeting the needs of the 5-year forecast.
The project was awarded Platinum Green Award by Building & Construction Authority of Singapore, the first ever for a privately developed industrial facility.
Services
- Facility Design
- Construction Oversight
Vendor Coordination
- Production Equipment
- Warehouse Automation
- ESD Facilitation
- Security
XILINX, Inc. AsiaPac Headquarters
Manufacturing Facility Design | San Jose, CA | Singapore
Project
Manufacturing, Engineering, & Distribution Center
Location
Changi Business Park, Singapore
Project Type
Industrial
Project Size
290,655 sf
Project Duration
18 months
Xilinx Inc is the leader in programmable logic devices with 50% of the world market share. In the brief to DCI, space efficiency and sustainability was a core design consideration.
The warehouse is designed with automation in mind with direct material handling conduits to the production floor. Smart features such as air flushing, light management system and intelligent environmental features provide a productive working environment.
Tasked to ensure the incorporation of worldwide demand projections to Xilinx’s headquarters, DCI proposed features that enabled a mere 1.1% increase in construction investment but reaps an expected $500,000 savings each year. DCI was responsible for analyzing production rates and capacity to assure that the resulting design was capable of meeting the needs of the 5-year forecast.
The project was awarded Platinum Green Award by Building & Construction Authority of Singapore, the first ever for a privately developed industrial facility.
Services
- Facility Design
- Construction Oversight
Vendor Coordination
- Production Equipment
- Warehouse Automation
- ESD Facilitation
- Security
CalAmp
Operational Supply Chain Design | Oxnard, CA
Project
Supply Chain & Manufacturing
Location
Oxnard, CA
Project Type
Industrial Profit Improvement
Project Size
150,000 sf
Project Duration
Design – 6-months
Conversion – 18-months
CalAmp is a technology company that specializes in telematics hardware and software and was struggling with high costs and an inefficient factory. DCI was engaged to assist in restructuring the Supply Chain, Physical, and Organizational design of the company to improve its performance and profitability.
The factory was redesigned into customer-focused modular teams along with all associated capital equipment. The Supply Chain was re-organized into major commodity bundles, contracts renegotiated in a Liability-limiting, highly flexible procurement framework, and overall material costs were reduced by 35%. Demand-pull logistical technologies were implemented in the factory execution systems, reducing WIP and FG levels by 60%. New Product Introduction teams were developed reduce time-to market and customer satisfaction.
The company’s operations were successfully turned around and profitability rapidly improved. The company's stock moved from less than $2 per share to over $45 per share within 2 years of its transformation.
Services
- Lean Manufacturing
- Facility Design
- Supply Chain Strategy
Vendor Coordination
- Production Capital Equipment
- Information Technologies
- Direct Material Suppliers
CalAmp
Operational Supply Chain Design | Oxnard, CA
Project
Supply Chain & Manufacturing
Location
Oxnard, CA
Project Type
Industrial Profit Improvement
Project Size
150,000 sf
Project Duration
Design – 6-months
Conversion – 18-months
CalAmp is a technology company that specializes in telematics hardware and software and was struggling with high costs and an inefficient factory. DCI was engaged to assist in restructuring the Supply Chain, Physical, and Organizational design of the company to improve its performance and profitability.
The factory was redesigned into customer-focused modular teams along with all associated capital equipment. The Supply Chain was re-organized into major commodity bundles, contracts renegotiated in a Liability-limiting, highly flexible procurement framework, and overall material costs were reduced by 35%. Demand-pull logistical technologies were implemented in the factory execution systems, reducing WIP and FG levels by 60%. New Product Introduction teams were developed reduce time-to market and customer satisfaction.
The company’s operations were successfully turned around and profitability rapidly improved. The company's stock moved from less than $2 per share to over $45 per share within 2 years of its transformation.
Services
- Lean Manufacturing
- Facility Design
- Supply Chain Strategy
Vendor Coordination
- Production Capital Equipment
- Information Technologies
- Direct Material Suppliers
Pure Fishing
Manufacturing Facility Design | Spirit Lake, IA
Project
Operations, Manufacturing Fabrication & Assembly
Location
Spirit Lake, IA
Project Type
Industrial
Project Size
300,000 sf
Project Duration
Design – 6-months
Conversion – 9-months
Pure Fishing is an 80-year old company with storied brands such as Berkeley baits and Abu-Garcia reels and was struggling to keep up with the demands of world-class customers such as Walmart. The company was generating obsolete inventory and not meeting its customers’ On-Time Delivery expectations
DCI was engaged to assist in the physical and organizational transformation of the company into highly focused, high-volume, factories based on Lean Manufacturing Methods.
The factory was divided into individual business units with operational KPIs and customer-focused organization structures, and then physically redesigned to meet its externally-focused demands for line, bait, rods, and reels.
The company’s operations were successfully turned around and profitability rapidly improved. It later attracted a $1.3B investment from a Private Equity firm.
Services
- Lean Manufacturing
- Facility Design
- Construction Oversight
Pure Fishing
Manufacturing Facility Design | Spirit Lake, IA
Project
Operations, Manufacturing Fabrication & Assembly
Location
Spirit Lake, IA
Project Type
Industrial
Project Size
300,000 sf
Project Duration
Design – 6-months
Conversion – 9-months
Pure Fishing is an 80-year old company with storied brands such as Berkeley baits and Abu-Garcia reels and was struggling to keep up with the demands of world-class customers such as Walmart. The company was generating obsolete inventory and not meeting its customers’ On-Time Delivery expectations
DCI was engaged to assist in the physical and organizational transformation of the company into highly focused, high-volume, factories based on Lean Manufacturing Methods.
The factory was divided into individual business units with operational KPIs and customer-focused organization structures, and then physically redesigned to meet its externally-focused demands for line, bait, rods, and reels.
The company’s operations were successfully turned around and profitability rapidly improved. It later attracted a $1.3B investment from a Private Equity firm.
Services
- Lean Manufacturing
- Facility Design
- Construction Oversight
Harmonic, Inc. Amplifier Manufacturing
Facility Design | Lean Conversion | San Jose, CA
Project
Lean Manufacturing, Facility Design
Location
San Jose, CA
Project Type
Industrial
Project Size
30,000 sf
Project Duration
12 months
Harmonic is leading the transformation for video, cable and media companies, with smarter, faster, and simpler solutions. Increased demand resulted in order high backlogs and longer production cycle-times that DCI addressed with Demand-pull production technologies.
- Modular manufacturing facility design maximized flexibility for future changes
- Production rate and capacity analysis-driven design
- Point-of-use inventory storage with auto-replenishment
- Dock-to-stock supplier awards to improve efficiency.
- 30% reduction in material costs with improved strategic procurement methods.
- Design met the needs of the 5-year forecast.
- 2x increase in capacity and inventory turns.
Services
- Facility Design
- Construction Oversight
- Supply Chain Strategy
Vendor Coordination
- Architects
- Construction Trades
- ESD Facilitation
- Raw Material Suppliers
Harmonic, Inc. Amplifier Manufacturing
Facility Design | Lean Conversion | San Jose, CA
Project
Lean Manufacturing, Facility Design
Location
San Jose, CA
Project Type
Industrial
Project Size
30,000 sf
Project Duration
12 months
Harmonic is leading the transformation for video, cable and media companies, with smarter, faster, and simpler solutions. Increased demand resulted in order high backlogs and longer production cycle-times that DCI addressed with Demand-pull production technologies.
- Modular manufacturing facility design maximized flexibility for future changes
- Production rate and capacity analysis-driven design
- Point-of-use inventory storage with auto-replenishment
- Dock-to-stock supplier awards to improve efficiency.
- 30% reduction in material costs with improved strategic procurement methods.
- Design met the needs of the 5-year forecast.
- 2x increase in capacity and inventory turns.
Services
- Facility Design
- Construction Oversight
- Supply Chain Strategy
Vendor Coordination
- Architects
- Construction Trades
- ESD Facilitation
- Raw Material Suppliers
DeHart Consulting
DeHart Consulting is unique among manufacturing management consulting firms in that we use a team-based approach in the vast majority of our assignments.
* The HP, KVH, CalAmp, Xilinx, Fujitsu, Emulex, and Harmonic logos are registered trademarks of their respective corporations in the U.S.
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