Large-Scale Manufacturing Renovation
Genesis joined forces with Bayer Healthcare to navigate the intricacies of modernizing a historic 1940s structure. Through rigorous planning, application of state-of-the-art EPCM techniques, and a dedication to minimal disruption, this partnership successfully transformed an older building into a contemporary manufacturing facility.
Genesis’ approach to their Advanced Manufacturing Systems helped this market leader increase their operational efficiency. By integrating an Automated Ingredient Dispensing/Mixing System, we streamlined their process, resulting in faster manufacturing and consistent product quality; and within their Continuous Coating Operation, we facilitated a smoother coating process to increase productivity and ensure product quality.
Recognizing the challenges posed by ongoing construction, our team phased the construction so that activities were carefully planned in isolated segments, allowing regular manufacturing operations to continue without disruption. Through collaboration with Bayer’s Site Operations teams, we were able to gain alignment and move forward seamlessly. We also implemented a parallel qualification and construction strategy. This practical approach expedited the turnover process, ensuring that the facility could be occupied promptly once construction was completed.