In addition to experience as production engineers, factory construction requires a comprehensive understanding and know-how of building construction, equipment installation, and more. This is not something that can be quickly learned or acquired through short-term training; it often involves on-the-job training (OJT) with experienced seniors and learning from failures, which are valuable assets in themselves.

The process from factory building and maintenance to the installation, adjustment, and operation of equipment after completion is fraught with continuous troubles. Coordinating daily with construction companies, equipment manufacturers, installation teams, and transportation companies to solve problems on-site is crucial for managing the construction schedule as planned. Safety management becomes especially important as fires or injuries can significantly impact the startup phase.

Furthermore, the costs related to production preparation can be very high, making it important for production engineers to manage these expenses within the budget. Therefore, having a measure for construction duration and costs is also necessary.

As the main factory became too cramped, we commissioned a major general contractor to construct a two-story factory (with a total floor area of 128,800 sqm) in an industrial park, divided into phases I through III.

I was part of a three-person team responsible for Phase II of the construction (with a total floor area of 52,400 sqm).

The construction company resolved issues that arose during the construction according to the architectural blueprints. During the finishing stages of construction, there were many adjustments related to the preliminary installation of production equipment and foundational work (related to the building).

Due to its proximity to the sea, the entire site was raised, and special construction methods were employed, such as driving piles down to the bedrock on reclaimed land. At the time, this resulted in the construction of Japan’s largest single building exceeding 120,000 sqm. Furthermore, the factory was designed to optimize information and logistics flow from the entrance to the exit.

We decided to establish a new factory in Eastern Europe and entrusted a major general contractor with the construction of a single-story factory (with a total floor area of 50,000 sqm).

Two of us were responsible for this project.

Due to various problems arising daily, we held regular meetings every day. We organized the issues that occurred each day, assigned responsibilities, set deadlines, and followed up daily. Amidst the new challenges (country, ethnicity, language, European customers, collaborating companies, etc.), we established a European hub.”

We transformed an aluminum piping factory (two-story building with a total floor area of 5,000 sqm) into a commercial packaging facility.

Two of us were in charge of this project.

After relocating the piping equipment, we cleared out the remaining discarded equipment, as well as air conditioning ducts, air pipes, steam pipes, electrical ducts, and wires that were hanging from the factory’s beams.

Once the factory was cleared, we conducted inspections and maintenance on various systems including the substation, industrial water supply devices (inspection and disinfection), the septic system, repairs for leaks, air conditioning systems, and replacement of shutters including the installation of quick shutters. We also worked on the factory’s oil recovery facilities, supported notifications to river management organizations, and provided assistance with notifications for specific facilities.

We implemented a systematic commercial packaging line that includes milk run for part pickups and multiple deliveries, and introduced a cardboard box manufacturing machine capable of producing boxes in the smallest unit of one box.

Currently, there is a trend of recovery from the COVID-19 pandemic, and it is anticipated that securing construction companies and workers will become more difficult. In response to the labor shortage, it is considered necessary to elevate the level of construction management through the generation of flexible ideas and improvements in construction work.