Master Planning for Manufacturing: Designing Beyond the Assembly Line
By: Stephen A. White, ASLA, OALA, LEED AP | Director of Urban Design & Landscape Architecture
Volvo South Carolina Plant Expansion
Article originally published by Area Development, and can be found on their website here.
The Detroit factory where Henry Ford first began mass-producing automobiles had a transformative impact not just on the auto industry but on manufacturing and business practices across all industries. However, that factory was singular in purpose—assembling a Model T as quickly and uniformly as possible.
Today, while optimal efficiency in production remains a primary goal, modern manufacturing facilities have evolved to serve a broader purpose. These facilities can now have a transformative impact on the communities where they reside. They not only improve the quality of life for both workers and residents but also spur the development of critical infrastructure and services to meet growing local needs. By achieving these holistic benefits, manufacturing plants contribute greatly to the sustainability and long-term success of their surrounding areas.
As manufacturing facilities shift from being solely production spaces to becoming catalysts for community progress, the complexity of their design and construction has increased. Fortunately, engaging in a comprehensive master planning effort helps navigate this complexity. It ensures the process remains efficient, allowing production lines to be operational swiftly while setting the foundation for broader community benefits.
Modern manufacturing facilities do more than produce goods—they transform communities.
The Master Planning Process: A Path to Success
To navigate the complexities of large-scale manufacturing projects, a thorough master planning process is essential. This begins by assembling a project team with expertise in industrial facilities and engaging stakeholders early to inform key decisions. Such collaboration significantly reduces delays and roadblocks as the project progresses.
A well-detailed master plan helps guide site selection, balancing costs with incentives, labor availability, and community development goals. A reliable workforce is one of the most critical factors for success, and many manufacturing facilities establish relationships with local educational institutions to create vocational programs tailored to their needs.
Here are five key considerations for optimizing the master planning process:
1 Transforming Communities with Manufacturing Facilities
Bringing a facility online is just the beginning. Local infrastructure and services reach full capacity often follows the plant’s opening. For example, healthcare services—critical to community well-being—emerge after a sufficient workforce is established. In areas like Kishwaukee and Valparaiso, Indiana, healthcare facilities followed the arrival of thousands of well-insured workers who came to support new manufacturing sites.
Alongside new developments, there's been a rise in the adaptive reuse of existing structures for manufacturing. When a manufacturing process doesn’t require highly controlled environments, repurposing older buildings can provide a faster time to market while often transforming a corridor or district of a community. Yet, retrofitting these facilities presents challenges—such as adapting outdated bay spacing and ceiling heights initially designed for older production methods.
2 Workforce Considerations and Cultural Adaptation
In addition to technical skills, cultural factors play a role in recruiting a global workforce. Manufacturing facilities must address language barriers, business customs, and cultural traditions to create an inclusive and efficient work environment. Early integration of these resources into the planning process can ensure that manufacturing facilities benefit from cultural diversity and avoid potential conflicts.
The surrounding communities must also prepare for the rapid growth that manufacturing facilities can bring. This includes developing new residential areas, schools, and service providers. Manufacturers can position themselves as valuable corporate citizens collaborating with local governments and civic leaders, contributing to long-term community prosperity.
3 Site Selection and Adaptive Reuse
Selecting the right site is critical for maximizing tax incentives and attracting a skilled workforce. But beyond these practical concerns, site selection also plays a key role in integrating the facility into the community. Establishing partnerships with local colleges or vocational programs can ensure that a steady workforce flow of trained workers available to meet the plant’s needs.
Not every modern facility needs to be built from the ground up. Adaptive reuse, as mentioned earlier, is becoming increasingly common. Companies can leverage existing infrastructure to speed up their time to market, particularly when high-tech firms from overseas lease and modify U.S. properties. However, retrofitting does have its limitations, especially for specialized processes requiring state-of-the-art environments or equipment with precise spatial requirements.
Moreover, adapting older structures necessitates carefully considering modern building codes, including smoke evacuation, fire safety, and egress strategies. Addressing these challenges—creating new rescue corridors or improving natural light—ensures that retrofitted buildings meet current safety standards while enhancing work environments.
4 Materials and Safety Concerns
As manufacturing materials evolve, so too do safety concerns. Lithium batteries, for example, pose significant hazards due to their volatility, and retrofitting existing buildings to handle such materials safely can be complex. Standard fire suppression systems, like sprinklers, may be ineffective in these cases, highlighting the unique challenges of adaptive reuse. However, when done correctly, these retrofits offer a faster time to market and are a highly sustainable option for manufacturers.
Even when upgrading older buildings, it’s essential to assess whether the structure can handle the demands of modern manufacturing. Equipment today requires stringent controls over humidity and temperature, meaning older facilities often now need significant environmental improvements.
5 Geotechnical Considerations and Infrastructure Demands
Given the massive size and heavy equipment housed in manufacturing facilities, geotechnical testing is crucial to ensure the site can support necessary loads. Hundreds of boreholes might be drilled to detect varying soil conditions, and unexpected underground obstacles, such as utility lines, must be factored into the project.
Beyond geotechnical concerns, the evaluation of existing civil infrastructure is equally vital. Access to highways, air, water, and rail freight is necessary for shipping products and raw materials. Likewise, the capacity of local utility providers to meet increased demands—particularly during extreme weather events—must be carefully considered.
The surrounding roadways must also be able to handle traffic generated during both construction and operation. Collaborating with local agencies to extend or improve roads can streamline development and reduce costs.
A well-detailed master plan is essential for balancing costs, workforce needs, and community goals.
Case Study
NAC Tiger Site Update:
Integrated Zoning and Stormwater Management
Project Overview
The NAC Tiger site exemplifies a holistic approach to zoning and sustainable stormwater management. The site is divided into two key zones: the Employee/Visitor Access Zone and the Manufacturing Zone. This clear delineation supports operational efficiency and safety while creating a cohesive campus layout.
Zoning and Site Functionality
Employee/Visitor Access Zone: Strategically designed to facilitate smooth circulation and public interface, this zone includes green spaces and pathways, fostering a welcoming and accessible environment.
Manufacturing Zone: Dedicated to high-intensity industrial operations, the zone maximizes functionality while minimizing disruption to adjacent areas.
Stormwater Management Strategy
The project integrates a robust stormwater management system designed to handle significant rain events, ensuring sustainability and resilience:
Detention Swales: Constructed with a gentle 6-to-1 slope, these swales detain water to control runoff and reduce flooding risk.
Storage Capacity: The system offers a 150-acre-feet storage capacity, detaining water for up to 24 hours and discharging at 60 cubic feet per second (cfs), ensuring efficient water management.
Rainwater Flow Optimization: The design leverages swales and detention basins to collect, store, and gradually discharge stormwater, reducing strain on local infrastructure.
Environmental and Operational Benefits
Enhanced site sustainability through effective water retention and slow discharge.
Mitigation of flooding risks, protecting both the natural environment and built infrastructure.
Clear zoning ensures safety and productivity by separating visitor-friendly and operational areas.
This case demonstrates how thoughtful site design and engineering can balance functionality, safety, and sustainability, serving as a model for future developments.
Conclusion: Master Planning for Success
Bringing a manufacturing facility from conception to start-up is a monumental logistical feat. While the design and construction of the physical plant are significant challenges, the facility's success extends far beyond its walls—it must be seamlessly integrated into the community.
A comprehensive master planning process ensures that every stakeholder is involved, every detail is addressed, and the project is set up for long-term success. With the right team and approach, the planning process can operate as smoothly as the assembly lines Henry Ford once envisioned, creating a lasting impact on the industry and society.
Stephen A. White
ASLA, OALA, LEED AP
Senior Vice President
Director of Urban Design & Landscape Architecture
Chief Strategy Officer
As Director of Landscape Architecture and Urban Design at Albert Kahn, Stephen’s responsibilities include seamlessly designing environments through collaborating with clients, teams and consultants to deliver thoughtful, sustainable solutions. With decades of experience in landscape architecture, urban design, master planning and more, Stephen aims to design spaces that improve the lives of each project’s community.