NEW CARPET MANUFACTURING FACILITY
New carpet manufacturing plant designed to produce carpet for the commercial market. Shaw Industries, Inc. contracted FDG to masterplan the infrastructure for the entire 1,400,000-SF new facility and to design the first phase of 650,000 SF. This facility is the world’s largest carpet tile production facility.
CARPET WAREHOUSE EXPANSION
Carpet warehouse expansion designed to produce carpet for the commercial market. Shaw Industries, Inc. contracted FDG to design the 150,000-SF expansion.
The purpose of this project was to study Shaw’s entire carpet samples supply chain process, which consists of distribution manufacturing, and purchasing (and receiving). An overall value stream mapping was performed on the supply chain to clearly identify value-added and non-value-added activities. In order to drastically reduce non-value-added activities, an innovative design was developed to completely re-engineer the process by introducing sophisticated technology such as Automatic Storage and Retrieval Systems (ASRS), Vertical Lift Modules (VLM), Manufacturing Cells, Racking Systems, Information Systems, and cutting-edge consulting practices (Six Sigma, Lean Manufacturing, And Theory Of Constraints).