Lear Corporation is a Fortune 500 company headquartered in Southfield, Michigan, which focuses on integrating complete automotive interior packages, including seat systems, interior trim and electrical system components for leading automotive manufacturers.
The Zanesville complex—the historic American Encaustic Tile Factory—is a mammoth 465,000 square-foot manufacturing operation, with core products of auto junction boxes, switches and other purpose-driven electric systems.
This was our first collaboration with Lear.
Challenges
Overseas Assembly Lines Relocated
Because of the exacting requirements of the assembly-line process work, Lear and MCR decided to use the Design-Build approach to retrofit the old factory space.
An accelerated two-month construction schedule complicated these successful assembly-line “transplants” for Lear:
Disassembly of Assembly Lines from Indiana and Spain
Relocation of both assembly lines to the Zanesville plant
Reassembly, testing and phased operation to full line capacities
Features
Auto Component Assembly Line Installed with Important Facility Upgrades
65,000 square feet of extensively remodeled factory space within the existing 465,000 foot complex in Muskingham County
62,000 square feet of “clean room” auto parts manufacturing
30,000 square feet of new “Class A” office space
New switching and load center facilities
Extensive compressed air, process piping and conduit installation
Specialty epoxy flooring systems for durability and safe, secure footing
All new fire protection, plumbing, heating and cooling
Restroom upgrades to existing facility
Reassembly and adjustment of assembly lines until full production capacity
Results
From The Ends of The Earth—To Zanesville
Our project team traveled from Tarragona, Spain (60 miles SW of Barcelona) to Huntington, Indiana, to assess the equipment that would be relocated.
The finished work enabled Lear to quickly mobilize the assembly line and gear up to full production operations at their plant.
In the new mobile global marketplace, “transplanting” assembly lines—even entire facilities—is a developing industrial market for MCR Services, Inc.
