Vinyl-X Site Plan

The company in this case study manufactures a specialty product of vinyl plastic. The distribution system for this product was experiencing dramatic changes and the firm had established a prominent position. Their growth had averaged 17% annually for a number of years and future projections were for continued growth near this level.

The "Initial Site" shows one of their factories at the beginning of this facility planning project. Each phase of expansion builds on the previous in a logical way that enhances material flow and, ultimately, maximizes utilization of the site. 

This plan balances space between manufacturing, warehouse and administrative office areas. Much of the space is built initially as low-cost warehouse. Some of this original warehouse space is later upgraded for manufacturing.

The plans below span a period of about twenty years and the original plans have been followed closely. A recent photograph is at bottom.

View from the Southwest after the Phase II expansion

Site Plan Color Code

Initial Site

This was the site at the beginning of the planning project. Extrusion occupied about half of the under-roof area. Resin arrives by rail on the East side and is stored in silos. Parking space was already short and many employees park on the grass.

Phase I Expansion

Expanding markets required additional office space and parking. Additional extrusion capacity came from upgrading existing extruders and two new extruders within the extrusion area. Significant additional warehouse space was required because of many new SKUs in addition to increased volume.

Phase II Expansion

This expansion upgrades some warehouse space to extrusion space. Additional warehouse is added to the  North side. Docks and truck maneuvering space was added in a way that provides for more warehousing later.

Site Saturation

This final expansion uses all available space on the site (Site Saturation). It includes another office addition, more employee parking, more warehouse space and conversion of additional warehouse space to extrusion.