Diageo was under regulatory deadline to produce and bottle all of its popular Bulleit Bourbon in Kentucky by end-of-year in order to continue to brand it as Kentucky bourbon. Dennis Group executed the complete renovation of an existing aging warehouse including underground plumbing, lighting, and process systems.
This project involved converting Diageo’s on-campus warehouse to a bottling hall. Two lines were relocated from their Relay, Maryland facility, with care not to disrupt operations in that plant. To facilitate a faster start-up, workforce training was coordinated in advance.
Smart design principles were used to redesign line layout, reducing number of required operators, and simulation modeling helped right-size the bottle accumulation mass, reducing the process batching time by 50%.
This facility was running at full capacity only five months after the start of demolition.
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