Ford Motor Company – Romeo Premium V-8 Engine Program

General Scope of Project: The Romeo Premium V-8 Engine Program was a CM Project for Ford Motor Company to manage production equipment modifications and installations for their new V-8 Engine Program. The project consisted of approximately 250,000 square feet of facilities relocations/renovations and 440,000 square feet of new and reworked equipment installation. The work included the following:

  • Removal and demolition of the existing 2V cylinder head and 4V crankshaft departments including overhead utilities and support facilities
  • Removal and replacement of the floor slab for the new block and crankshaft departments
  • Revision of underground utilities as required for the new equipment layouts
  • New and reworked overhead mechanical & electrical utilities as required for the new department equipment layouts including mist/dust collection, coolant system piping, utility piping, busduct, secondary electrical distribution and lighting.
  • Miscellaneous other floor work and facilities renovations in the connecting rod, engine assembly and head & cam assembly departments
  • Purchase and installation of overhead crane systems in all departments
  • Installation of new Process Coolant and Chip Handling Systems

Construction Challenges

The main challenges of the project related to working in and around continuing Owners operations. There was limited access to the construction areas with very little room to maneuver and limited lay down area. All construction took place within enclosed temporary construction walls that divided the construction areas from the plant production areas. The project was successfully completed without once affecting production operations.

Value Analysis/Value Engineering

The team saved the Owner $3.9 million in VA/VE savings over the life of the project.

Project Information

Market: Automotive
Client: Ford Motor Company
Location: Romeo, Michigan
Project Size: Facility Renovations & Relocations: 250,000 Square Feet | New & Reworked Equipment Installation: 440,000 Square Feet
Project Cost: $44,800,000
Project Date(s): 11/01/06 – 08/01/09
Delivery System: Program Management, Construction Management
Special Remarks: Architect / Engineer: Ghafari Associates, Inc.

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