APOLLO AUTOMATIONJAMES WARREN · ENGINEERING & PROJECT LEADERSHIP

CASE-135 · Engineering case

Five-Year Capital Planning and Asset Lifecycle Roadmap

Built a five-year capital planning view linking asset lifecycle, packaging growth, utility risk, structural issues, workforce constraints, and logistics capacity.

Conceptual engineering visualization: Five-Year Capital Planning and Asset Lifecycle Roadmap
Conceptual engineering visualization · AI generated

Why the Work Mattered

Purpose and Operating Need

The plant needed a capital roadmap based on growth demand, aging assets, reliability risk, regulatory exposure, warehousing capacity, labor realities, logistics constraints, and production continuity needs.

Engineering Approach

Engineering Approach

Aligned five-year capital planning with 3% CAGR and increased retail-customer volume; prioritized packaging, utilities, and infrastructure investments by OEE impact, downtime risk, maintenance cost, safety audit findings, compliance exposure, and lifecycle replacement needs; added Line 1/Line 2 equipment age and maintenance-history assessment; 1973 palletizer; capper/labeler/casepacker/palletizer reliability losses; electrical containment failures from underground faults on West/Bulk side; utility trench restoration; sinking tanks in winery/bulk/drum-fill; washed-out concrete floor; Bldg 2 roof issue; staircase code compliance; wastewater panel orientation; well-water cooling concept; yard dog logistics; 10-12 days maximum onsite warehouse capacity; contract storage strategy; labor/wage/commute/competition considerations; customer-side shipment acceleration during acetator shutdown periods.

Outcome & Engineering Context

Outcome and Context

Improved capital prioritization and asset lifecycle governance.

Measures & Operating Detail

MeasureValueType & meaningAttribution & operating context
Growth CAGR3 %Scenario or Model Result
Planning assumption

Applies to: Five-Year Capital Planning and Asset Lifecycle Roadmap

3% CAGR assumption

Onsite Warehouse Capacity10 to 12 daysBaseline
Planning constraint

Applies to: Five-Year Capital Planning and Asset Lifecycle Roadmap

Onsite Warehouse Capacity

Engineering scope and design basis

Improved prioritization across end-of-life equipment, OEE losses, downtime exposure, maintenance cost, safety audits, compliance exposure, infrastructure degradation, and facility-growth constraints.

Improved capital prioritization, measured by a five-year roadmap aligned to 3% CAGR, increased retail volume, OEE impact, downtime risk, safety audits, and lifecycle replacement needs, by translating assetcondition, growth demand, utility risk, structural degradation, logistics constraints, and workforce factors into prioritized capital scope.

Five-year roadmap; 3% CAGR assumption; increased retail-customer volume; 10-12 days maximum onsite warehousing; Bldg 2 roof issue.

Actions, Methods & Controls

ACTIVITIES IN CONTEXT

Conceptual engineering illustration: risk reliability

TSK-000412 · Method

Combined Asset Lifecycle Review, OEE Analysis, Downtime Risk, Safety Audit Inputs, Structural Assessment, Electrical-Risk Diagnosis, Logistics Planning, Labor-Market Context, and Production-Continuity Planning

Five-Year Capital Planning and Asset Lifecycle Roadmap

Analyze Downtime, Capacity and Equipment LossesTranslate Operating Needs into Capital PrioritiesDevelop Capital Roadmaps and Investment PhasesPrioritize Investments by Performance and Lifecycle ValueAlign Production, Infrastructure and Workforce RequirementsModel Electrical Demand and Spare CapacityCoordinate Warehouse Capacity and Material Flow
Case: Five-Year Capital Planning and Asset Lifecycle Roadmap

Additional Technical Detail

Roles & contributions

  • Project Ownership

    Full lifecycle project ownership

    Direct Work

    Built the five-year capital roadmap from growth assumptions, OEE, equipment age, maintenance/safety/compliance risks, utility/structural issues, logistics and workforce constraints.

    Owned the full project lifecycle: capital planning and prioritization, need definition, feasibility and scope development, engineering and AFE justification, procurement and vendor coordination, construction sequencing and field oversight, commissioning, turnover, and post-startup support. Connected operating requirements with technical scope, funding decisions, execution readiness, and the needs of operations and maintenance.

Additional technical detail
Explore 7 detail records
  • Equipment age

    1973 palletizer

  • Reliability finding

    Capper/labeler/casepacker/palletizer reliability losses

  • Electrical condition

    Electrical containment failures from underground faults on West/Bulk side

  • Foundation condition

    Sinking tanks in winery/bulk/drum-fill

  • Floor condition

    Washed-out concrete floor

  • Building condition and cost context

    Bldg 2 roof issue

  • Warehouse capacity constraint

    10-12 days maximum onsite warehouse capacity

All portfolio connections
All portfolio connections (24)
Related analysis and application artifacts

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