Crews consructed a freezer at the Just Desserts facility that was three time larger than its provious one.
Attend a cost-reduction workshop
Jim Kline, president of The EnSol Group and contributing editor for Baking & Snack, said a cost-reduction workshop early in the process can help establish areas where compromises can be made. In that workshop, bakers and construction companies examine schematic design and the cost it takes to complete the project. If the cost for certain items are $15 when the budget calls for $11, Mr. Kline explained, the two sides must sit down and go through every detail that determined that cost.
“Most often, the process becomes the sacrosanct piece and everything else is peripheral,” Mr. Kline said.
The level of finishes is often the first peripheral consideration to be compromised. Mr. Kline said it is not uncommon when costs exceed the budget to use different construction methods for different functional areas of the plant. For example, building offices with finish level that could be a showcase for visitors while designing the production area to be FSMA compliant and achieve SQF certification, and building the rest of the facility with functionality in mind, can save some capital cost.
Stay organized though project management
For a vision to be realized to its fullest potential, companies should engage in every aspect of the project.
Mr. Kline recommended developing an integrated schedule with all firms, including equipment suppliers, on a project. In the planning stages, companies should recognize that construction crews installing ventilation ducts or pipes for sprinklers overhead need to work in the same area where electricians are running wires for lighting. Mr. Kline said all of this must be coordinated to minimize disruptions.
“Typically, projects that are managed succinctly can come in at budget,” Mr. Kline said. “You get into overruns when there is not a project manager who is active, or when it goes long.”
The Austin Co. encourages company leadership to visit with designers and engineers to establish a connection to the project. This collaboration creates a sense of ownership in the plant and ultimately fosters a better working relationship and final outcome.
Just Desserts worked closely with its equipment manufacturers who brought a vast amount of knowledge and experience to the table, Mr. Mendes said.
“They also have a good understanding of some of the issues others may have, so we look to be actively engaged with manufacturers to gain from their applied experience,” he said.
Just Desserts also assigned individuals to manage each step in the process and made sure everyone understood the end goal to make the project a success. To avoid diffusion of responsibility and setbacks, Mr. Mendes said the company held periodic progress meetings to recalibrate the schedule, adjust the budget if needed and refine or modify who would assume certain roles in the process.
By following best practices like developing a detailed schedule and holding regular meetings and check-ins, any size project can be completed successfully. At that point, Mr. Mendes recommended conducting a final review with a thorough debriefing to learn from mistakes and evaluate the actual ROI, followed by a final determination if the goal was met or exceeded. Only then can a bakery see that dream facility become a reality.
