S. J. Bailey & Sons, Inc.

RELOCATION, CONSOLIDATION & REDESIGN OF UNFINISHED FURNITURE PLANT

Background: S. J. Bailey & Sons is an unfinished furniture manufacturer headquartered in Clarks Summit, PA with multiple facilities in the Northeast US. Aiming to increase sales, reduce work-in-process, and reduce logistics problems management decided to review the expansion and restructuring options at their two furniture plants. Their initial evaluation indicated that building and site constraints at the two operations prohibited significant improvement. A decision was made to build a new facility to replace the two existing plants and achieve their goals.

Situation: During initial planning management identified a suitable tract of land in Carbondale, PA. With a potential site identified, A. G. Raymond & Company was retained to assist in capital budgeting, space requirements/allocation, and process layout design. A project team consisting of Bailey’s vice president of operations and plant managers plus A. G. Raymond & Company staff was formed.

The first phase of work included a survey of the two existing production facilities to determine space requirements for the furniture manufacturing processes. Additional data on anticipated sales volumes, work-in-process levels, process routings, and other key parameters were gathered during the initial phase.

After analyzing the initial data, process flows, conceptual building drawings, and conceptual site plans were developed. Once the project team agreed on the proposed site configuration, A. G. Raymond & Company generated the project’s capital budget and schedule. The project team estimated potential operating savings from the single plant. Based on the resulting cost/benefit analysis, S. J. Bailey & Sons decided to proceed with the project.

With this decision the project advanced into the design phase. The project team was then expanded to include a local engineering firm. While this firm began detailed site and building design, A. G. Raymond & Company began collecting critical process design information. The first step involved cataloging all equipment at the two existing plants. Dimensions, individual machine/system layouts, and mechanical/electrical data were collected describing the equipment to be relocated. With this detailed information A. G. Raymond & Company produced scale equipment layouts, equipment schedule, project timeline, and bid specifications for the new dust extraction and wood-waste handling systems.

When all process layout and building details were approved, S. J. Bailey & Sons commenced with building erection and the relocation of their process equipment. New equipment was installed as required to supplement the relocated equipment. As of mid-August 1999 S. J. Bailey & Sons is settling into their new Carbondale plant on schedule and on budget.

Click here to view related photos.

A. G. Raymond & Company Inc. 1033 Wade Ave. Suite 102 Raleigh, NC 27605
Phone: (919) 831-0070 Fax: (919) 831-0072 Email: info@raymondnet.com