Transforming a Plant from Top to Bottom

The team in Frankfort, KY, has completed a major overhaul of the damper plant, a project that began in 2021 and transformed the workspace for nearly 200 team members.

We were able to lead a plant-wide GPS Champion project, working alongside Manufacturing Excellence, Corporate Services, EHS, Maintenance, and plant leadership teams over the last few years to upgrade and improve operations on nearly every level.

“Approximately 90% of the plant equipment was moved for better process flow,” said Charlie Logan, dampers plant manager. “We were able to take advantage of and follow other damper plants to optimize our facility and make the most of our space.”

Through strategic operational adjustments and a commitment to efficiency and flexibility, the team was able to free up nearly 20,000 square feet of space, which allowed us to take on this transformative project.

“We had the chance of a lifetime to improve efficiency and flow, as well as increase general purpose space. We utilized the expanded footprint to ramp up capacity from a production standpoint while maintaining breathing room for efficient production design,” said Mark Haase, dampers senior manufacturing director.

The efforts with this project led to a plant transformation that is already seeing success. The efforts to transform the plant have already had a significant impact, resulting in safer and more efficient day-to-day operations.

“Much in the way a homeowner might tear a wall down, bringing down the west wall in our facility helped with air circulation and created safer pedestrian walkways,” said Charlie.

Expansions on some of the floor areas allow for safer maneuvering of large units. New and more efficient equipment – large and small – replaced outdated components. Workstations were separated from being too close to one another. Plans increased the number of assembly tables from two to 12. Overall, the general flow of the plant was improved to advance pedestrian safety while increasing production capacity.

Over the course of the transformation, a number of improvements were designed and implemented deliberately for form and function. However, not all improvements impacted the direct manufacturing process. Investments, such as an upgraded break room and a new outdoor patio area, were made to enhance the workplace experience for our team members.

“The project was underway when I joined the Kentucky team,” said Corey Rogers, maintenance and facilities supervisor. “This project made it very clear how much we value teamwork, and how our working relationships are huge to the success of our company.”

Through the process, it has been exciting to share the successes of this transformative project, and how it made a great place to work even better. In addition to improvements on the business end, we’ve also focused on a safety-first production floor.

“The full transformation changed so much about our everyday business, but it did not harm production,” said Mark. “It’s important to take care of customers and one another, as always.”

It was as exciting as it was challenging, and a great example of the best in collaboration from across the company.

Transforming a Plant from Top to Bottom
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