Location: Glendale, Arizona USA
Completed: 2023
What We Completed
Roeslein teamed up with a long-time customer to engineer, design, procure and construct a state-of-the-art greenfield D&I plant in Glendale, Arizona. This facility boasts seven fully automated can making lines and has the impressive capability to run six different lines directly to the filling facility — an unprecedented achievement as the first plant in North America to do so.
What We Achieved
Throughout the four-year duration of this project, seven of the eight lines’ “first pallet” scheduled completion dates were hit on time with the first line coming in weeks early and the one missed line due to long lead equipment not being available for installation.
The most significant success and what we are most proud about is the overall safety of the project. Throughout the duration of the project, including the TTW project inside our client’s filling line, Roeslein and their contractors had zero lost time incidents.
What We Did Differently
One innovative solution during this project was the use of scanning and 3D modeling during the design phases. This allowed us to identify potential issues early in the process and streamline coordination between the engineering, construction and client teams.
Additionally, the use of Roeslein’s patented prefabricated modular components, specifically on one of Roeslein’s first fully outdoor Bulk Systems, reduced on-site construction time and resulted in seamless design changes in the field.
What We Faced
A major challenge was managing the logistical and engineering complexities during the global supply chain challenges faced around the COVID era. Our aggressive schedule of starting one line and moving to the next lines while juggling parts caused audibles from one line to the next. One example of this was securing temporary gear motors to start one line and then replacing those motors during production when the permanent motors arrived.
What We Learned
We learned throughout all phases of the project, from innovating the engineering to maintaining clear, frequent communication between engineers, constructors, and client. One standout lesson from an uncommon circumstance was to collaborate earlier with the building GC to prevent on-site clashes between building and process equipment.
What We Heard
The client expressed gratitude and high satisfaction with our commitment to safety and schedule. Our client’s record-setting start-up of these lines shows the high degree of quality that was achieved during the installation. Lastly and most importantly, our partnership with this customer and their trust of us to continue to be their integrator is the highest level of feedback we could receive.
How We Went Beyond the Ask
Both project and construction team members pulled out all the stops to hit our agreed-upon installation dates, including working Sundays, driving to other states for needed parts and using Roeslein’s deeply rooted engineering and construction management teams to steer on-site issues in the right direction.
Experienced can makers and motivated project team members streamlined their processes from drawing to the site. Our on-site team pushed themselves to safely and effectively hit green tag dates with minimal rework and overall customer satisfaction.
