RGD Case Study

Construction Management
Owners Agent

Novo Nordisk FP Expansion

An in-depth case study of a $32 million IPM project

Facility Type
Production Finishing & Packaging
Project Type
Construction Management
Timeline
15 Months

Project Scope

Novo Nordisk, a global healthcare company and world leader in diabetes care needed to increase the Flex Pen Finishing and Packaging capacity at Novo Nordisk Pharmaceutical Industries, Inc. (NNPII) production facility located in Clayton, North Carolina. The project included the following features: expanded manufacturing to accommodate assembly and packaging lines, a new warehouse, a second floor office area, and a loading dock as stated in the below Original BOD.

Original Basis Of Design

Novo Nordisk intends to increase the Flex Pen assembly and packaging capacity at Novo Nordisk Pharmaceutical Industries, Inc. (NNPII) production facility in Clayton, NC. To that end, Novo Nordisk plans to evaluate options for expanding the FlexPen® assembly line warehouse and packaging areas for the FlexPen® product at the Clayton, NC facility.

This Basis of Design (BOD) document focuses primarily on the currently preferred option for this expansion (Option 1).

For Option 1, the total estimated build-out will contain approximately 92,000 sq-ft of new space.

This proposed expansion will include the following features:

  • expanded manufacturing to accommodate one assembly line and one packaging line with the capability to add a future assembly or packaging line;
  • a new warehouse with dedicated +5°C cold storage warehouse for in-process and finished FlexPens®, and a dedicated ambient FlexPen® component and label warehouse;
  • a second floor office area, including space initially for 46 new work stations and 6 quiet rooms;
  • a loading dock on the north side of the expansion designed to accommodate two truck positions.

Key Success Points

  • Safety
    No lost time accidents occurred during this accelerated project.
  • Scheduling
    9 months from start of foundations to building dry-in and partial occupancy of critical manufacturing equipment.
  • Cost Control
    Met budget on accelerated schedule.
  • Quality
    Acquired temporary occupancy for production to begin on schedule, no delays due to quality.

Project Timeline

We completed a critical area of this project in 9 months from start of foundations to building dry-in and partial occupancy of critical manufacturing equipment.
August
RGD Awarded Contract
September
Ground Breaking Ceremony
November - December
Structural Steel Erection (740 Tons)
April
Building Dry-In of entire 92,000 square foot Building Expansion
June
Critical "Area D" Complete and Ready for Equipment and Occupancy
December
Project Complete, Occupancy Permit Received, All Areas Operational
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