Multi-Year Automotive Facility Modernization

As part of a multi-year modernization program at a 3M sq. ft. automotive assembly facility, Sylvan provided complete General Assembly conveyor and tooling upgrades, along with the installation of a new Robotic Wet 3 paint system. Working within a fully operational manufacturing environment, Sylvan delivered comprehensive multi-discipline support, including millwright, rigging, electrical, piping, and general construction services.

The project involved the installation of more than 5,000 ft. of conveyor, over 1,000 data drops, new robotic cells, tooling systems, upgraded ventilation infrastructure, and quality-test equipment across multiple production centers. Because production remained active throughout the program, all work required extensive planning, coordination, and sequencing to support ongoing operations while minimizing disruption. Major installation activities were executed during tightly controlled shutdown windows, often requiring the mobilization of up to 1,000 skilled tradespeople within a single week. Working in highly constrained spaces and around active production lines, Sylvan’s teams coordinated closely across trades and stakeholders to deliver complex upgrades safely and efficiently.

Through a coordinated, multi-discipline execution strategy, Sylvan successfully delivered major modernization upgrades while the facility remained fully operational. New conveyor systems, tooling installations, robotic cells, data infrastructure, ventilation improvements, and quality-testing equipment were integrated across multiple production centers with minimal impact to ongoing manufacturing activities.

By carefully sequencing work around production schedules and maximizing efficiency during shutdown periods, Sylvan helped strengthen the facility’s automation capabilities, improve long-term equipment reliability, and modernize critical manufacturing systems. The upgrades enhanced operational flexibility and positioned the facility to support evolving production requirements and future technology demands.