Doubling manufacturing capacity through integrated delivery and Lean construction
Market
Industrial Process
Key Services
Construction
Preconstruction
Self-Perform
Strategic Partnerships
Delivery Method
Integrated Project Delivery (IPD)Capacity
21,700 SFThe challenge
Procter & Gamble partnered with Alberici to expand its St. Louis home care products manufacturing facility with a 17,500 SF building addition, a new 4,200 SF process building and a three-bay loading dock expansion. The project doubled the plant’s production capacity while creating space for a future packaging line and accommodating increased shipments
Delivered through an Integrated Project Delivery (IPD) model, Alberici collaborated with Procter & Gamble and the design team under an Integrated Form of Agreement (IFOA), aligning all participants through shared risks, rewards and project goals. Lean construction principles guided collaborative design sessions and target value design workshops to maximize value while maintaining budget and schedule
Key Facts
2X manufacturing capacity through strategic facility expansion
Three-bay dock expansion accommodates increased outbound shipments
Over $400,000 in savings achieved through lean construction and collaboration
Challenge met
By applying lean planning from design through construction, Alberici helped reduce project costs by more than $400,000, approximately 4% of the project’s estimated value. Collaborative decision-making, target value design and continuous process improvements enhanced efficiency, maximized owner value and delivered the expansion in alignment with Procter & Gamble’s conditions of satisfaction.
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