Manufacturing · New ConstructionIn progress · 2027

EV Battery Cell Manufacturing Plant

Thousands of workers a day on one site. The schedule has to tell each crew where to be.

LocationKentucky

ClientConfidential

LocationKentucky

SectorManufacturing

Value$1.85B

Size3,000,000 sq ft

DeliveryEPCM

Duration40 months

StatusTarget 2027

Why it mattered

New manufacturing capacity has customers waiting on it before the slab is poured. The first production run is the date that matters, and everything else is a means to it.

The challenge

A battery joint venture is building a gigafactory to supply electric vehicle production. Dry rooms, process tools and utilities make it as complex as many semiconductor fabs.

At peak, several thousand craft workers will be on site daily. Without disciplined coding and trade sequencing, access, laydown and stacking problems would show up as lost productivity long before they showed up as late activities.

Our role

Integrated Master Scheduling (IMS)Resource Loading Earned Value Management (EVM)Project Controls Management Executive Scorecards

Schedule at a glance

The whole program, on one line.

Start to finish, as the schedule tells it. For work still in progress, the bar moves with today's data date.

StartMar 2024

Duration40 months

Target finishJul 2027

Progress—

Overlap with controlTrack outside dependenciesMeasure, do not estimatePlan the first run

How we held the date

Our approach, phase by phase.

The same disciplined sequence we bring to every engagement, shaped around what this project needed most.

PHASE 01PHASE 02PHASE 03PHASE 04

PHASE 01Overlap with control

Phased building turnover planned so tool installation could start well before the building was complete.

PHASE 02Track outside dependencies

Utility service, permits and equipment deliveries held as critical external milestones.

PHASE 03Measure, do not estimate

Earned value and quantity-based progress in place of opinion-based percent complete.

PHASE 04Plan the first run

Commissioning and production ramp-up scheduled with operations from the first baseline.

What changed

The difference we made

Measured the only way that matters: whether the date and the budget held.

Result 01Scale under command

More than 40,000 activities are managed in a structured, coded master schedule.

Result 02Labor curves that drive logistics

Resource-loaded craft curves inform recruitment, housing and site logistics months ahead of need.

Result 03Measured, not estimated

Earned value and quantity-based progress have replaced subjective percent-complete.

Services engaged

What we brought to it

Our work in Manufacturing

2.01.03Integrated Master Scheduling (IMS)

Integrated Master Schedules that bind design, procurement, construction and commissioning into one traceable program view, from board summary to field activity.

2.01.10Resource Loading

Labor, equipment and cost loading that turns a schedule into a feasible plan for people, plant and cash, and the foundation for earned value.

2.02.05Earned Value Management (EVM)

Earned value systems that integrate scope, schedule and budget, measure performance without opinion and forecast completion from evidence.

2.02.01Project Controls Management

Schedule, cost, change, risk and reporting designed, staffed and led by RichardBarkley, running to a disciplined monthly cycle from the first period.

2.05.05Executive Scorecards

Concise executive scorecards that tie strategic objectives to delivery, cost, safety and risk measures, with clear owners and thresholds.

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