Integrating a new battery platform into a live gigafactory without disrupting existing operations.

3,506 assets, one active cleanroom, zero disruption

A live gigafactory upgrade means every relocated asset has to come out, and go back, while maintaining the site’s active cleanroom conditions and existing operations. Beck & Pollitzer supported a joint venture between an American automotive manufacturer and a Korean battery industry leader with exactly that challenge, integrating a new battery platform into an existing, fully operational factory in Glendale, Kentucky.

The scope covered the dismantling, packaging and relocation of 3,506 individual items, from delicate cell packaging units to heavy industrial conveyors, all within an active cleanroom environment where particle control had to be maintained throughout.

A bilingual team, seven OEMs, 1,487 skids prepared

Given the joint-venture structure of the client, Beck & Pollitzer deployed a hybrid Korean-American project team to mirror it directly, working with seven different equipment OEMs to identify and handle each asset correctly.

Mobilising up to 50 skilled operatives, the team delivered the full scope over 117 days, coordinating equipment movement from the cleanroom, formation area and West Yard into a single consolidated transport zone.

3,506 items relocated, active cleanroom status protected

With cleanroom protocols maintained throughout, the project protected the facility’s active status while every one of the 3,506 items was identified, packaged and moved to its consolidated transport zone.

The result gave the joint venture a fully relocated technology upgrade, delivered across 29,467 project hours without disrupting the facility’s ongoing operations.