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Ford Motor Company: Chicago Assembly Plant Expansion

The Customer Challenge

The company that put the world on wheels needed a partner that could help upgrade its operations. In support of its 2020 Explorer Program, Ford Motor Company required extensive facility renovations at its sprawling Chicago Assembly Plant. Specifically, the challenge was to install nearly 2,000 feet of precision-welded stainless steel piping for a new Freon system. The complex piping infrastructure extended throughout the plant, including many areas that needed to remain fully operational throughout the project execution period.

The Sylvan Solution

Knowing the power of partnership and collaboration, Sylvan leveraged its strong relationship with Pipefitters Local 597 to successfully install the required piping for the new Freon system, all without disrupting assembly operations during a 3-week window in July 2018. Working with Local 597 foremen and tradespeople – which included supervision and manpower totaling over 40 people – Sylvan’s project management team completed the system to the client’s satisfaction with amazing speed and workmanship.

The Result

Employing over 150 tradespeople, Sylvan successfully met all required project schedule dates. Following the July 2018 production shutdown, Sylvan began planning for the even more challenging task of completing this current contract in the Trim Shop, as well as two additional contracts in the Trim Shop and a large piping project in the Body Shop. These projects were scheduled during a 4-week window in March 2019. Over 30,000 pipefitter manhours were expended with no lost time to injuries. We think Henry Ford himself would approve.