The Challenge:

The scheme comprised of the extension to an existing manufacturing facility for Protolabs, the world’s fastest digital manufacturer of custom prototypes and low-volume production parts.

The project included a 50,000 sq ft extension to the existing manufacturing facility and a new two-storey office in Telford, Shropshire.

The extension has seen an increase of its already significant factory at Halesfield 8, which previously totalled nearly 100,000 sq ft of space, to meet an increasing demand for moulded parts for a range of products and industries.

The challenge for Kier was to undertake this extension whilst ensuring the existing plant continued day to day production, unaffected by our works, and ensure that both Kier and Protolabs had optimum use of the loading bay area whilst undergoing construction.

The Solution:

Our pre-construction team came up with a series of logistics plans to plan the sequence of works, ensuring the construction phase works were unhindered and Protolabs could continue their daily production delivery runs.

Kier’s vast experience of working within live environments has ensured that all operations at the Protolabs site were maintained, ensuring the extension to the existing factory was delivered with no disruption to the current production. Works were planned to enable Protolabs and Kier to be able to simultaneously access the loading bay area which was a vital area of access and deliveries, whilst the construction phase was ongoing, ensuring no lost production by either party.

The client requested early access to the building to complete the fit-out works, however, Kier were able to use their detailed logistics strategy to hand over the building to the client five weeks early. Procurement was completed well in advance of the procurement programme, which also helped facilitate the early handover of the project by the site team.

The Impact:

The project completed early January 2020, achieving 141,750 accident-free hours and a Considerate Construction Scheme (CCS) score of 40/50. The project also achieved a social value impact output of £1.07 per £1 spent throughout the project.

On completion of the project, Protolabs have been able to employ nine local residents to begin work at the new factory, with a view to employ a total of 60 local people by 2021.

The project has achieved client satisfaction scores of 9/10 throughout the project.

" As a client, I am happy with the site team and they have given me confidence in the delivery of the product. "
Andrew Green Facilities Manager Protolabs

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