Production Line Decommissioning

Project Overview

Led the complete decommissioning of a production assembly line, managing the safe removal and disposal of production equipment while coordinating the transition of remaining operations to modernized production lines. This project was part of a larger manufacturing optimization initiative to consolidate operations and improve facility utilization.

Challenges

• Safely disconnecting and removing complex automated assembly equipment with minimal disruption to adjacent production lines
• Coordinating equipment removal schedules around active production operations
• Ensuring proper documentation of electrical, pneumatic, and data connections for future reference
• Managing disposal and potential reuse of equipment components and spare parts inventory
• Recovering valuable facility space for future manufacturing capacity expansion

Approach

Developed a comprehensive decommissioning plan that prioritized safety, operational continuity, and equipment value recovery. The project involved detailed documentation of all equipment specifications, coordinating with facilities and maintenance teams for safe disconnection, and managing logistics for equipment removal.

Worked closely with production planning to ensure smooth product transitions to alternative production lines (RDR14 and RDR03), minimizing any impact on customer delivery schedules. Identified reusable components and spare parts that could be repurposed for other production lines, reducing waste and providing cost-effective spare parts inventory.

Key Activities

• Equipment inventory and documentation of all connection points and specifications
• Safety planning and coordination with maintenance teams for disconnection procedures
• Scheduling and logistics management for equipment removal
• Spare parts evaluation and redistribution to other production lines
• Floor space planning and preparation for future manufacturing use
• Final inspection and documentation of decommissioning completion

Results

• Successfully decommissioned entire production line without safety incidents
• Recovered significant manufacturing floor space for future capacity expansion
• Identified and redistributed reusable components valued at thousands of dollars
• Completed project on schedule with no disruption to adjacent production operations
• Established decommissioning procedures and documentation standards for future projects

Impact

This decommissioning project demonstrated effective project management and cross-functional coordination in a complex manufacturing environment. The recovered facility space enabled future production capacity expansion, while the systematic approach to equipment removal established best practices for similar facility optimization projects. The successful parts recovery and redistribution provided ongoing cost savings for maintenance operations across multiple production lines.