“Overall, our onsite job labor has decreased about 10 percent due to the quality of product coming out of our new Advanced Manufacturing facility,” says Tom Wengert, Vice President of Baker Group’s Sheet Metal Business Unit.

“Our new manufacturing methods make us sharper and more competitive,” Wengert says. After products are designed, they are manufactured in an environment featuring an efficient workflow, less clutter, better air and better lighting, so products are protected, sealed and delivered to the job site at a quicker pace – all of which enhances value for clients.

Improving Cost, Quality & Speed of Delivery
Steve Brommel, Virtual Design Construction Manager for Baker Group, says, “Scanning and 3D modeling allow us to design and perfectly prefabricate a wide range of construction products – sheet metal, plumbing, piping and electrical, security and automation controls. Combined, these technologies help us reduce project time, perform at less cost and increase the quality of product.”

Once prefabrication begins in Baker Group’s new Advanced Manufacturing facility, products benefit from being prefabricated in larger spaces dedicated to individual trades, plus a 9000-sq. ft. multi-trade manufacturing area. This allows all trades to work simultaneously, which wasn’t previously possible.

Additional production gains are achieved through the facility’s configuration, sound processes, skilled workers and new equipment. Just a few examples:

• New 250-ton press brake expands Baker Group’s ability to work with heavier, thicker metals more quickly.
• New 5-foot sheet metal coil machine allows straight-line production of ductwork and other metal products. Raw product comes in one door and goes out the other door as finished product.
• Hoist equipment allows Baker Group to quickly and cost-effectively “bolt up” assemblies that were previously done in the field.
• Improved industrial specialty metal fabrication area with clear area capture, handling and overhead cranes.

Above All, Increased Production Benefits Clients
Recently, one of Baker Group’s major clients needed more than 500,000 lbs. of metal prefabricated for ductwork. Wengert says, “With our Advanced Manufacturing capabilities, we were able to provide a 40 percent productivity gain over what could have been done in our previous facility. It was delivered to the job site much sooner.”

Brommel adds, “For another client, using equipment drawings and structural models allowed us to fabricate much of the piping in our facility, before it was needed onsite. This not only reduced costs and increased product quality for our client, but it also shaved months off the construction schedule.”

Since moving into our new Advanced Manufacturing facility, “We are performing shop welds at nearly one-third the labor of field welds. In the last three months, we have performed more pipe welds than we did in a full year at our previous facility,” Brommel says.

Wengert adds, “People who have worked with us know what to expect from us. They know we will do what we say we will do. This facility has given us the opportunity to be more competitive and bring even more value to our clients.”

For a look inside Baker Group’s Advanced Manufacturing facility, watch our video.