In the spring of 2021, we set out to transform an outdated two-story, 100,000-square-foot building with good bones into an impressive state-of-the-art facility. We viewed the investment as a critical step toward securing our position as a globally recognized contract component manufacturer for medtech, aerospace, space exploration, and other high-tech mission-critical applications. So, we partnered with an exceptionally qualified team of architects, designers, engineers, consultants, advisors, and a general contractor and embarked on a winding journey that we expect to complete in Q2 of this year.
In this post, we’re sharing insights from KMM’s CEO, John Shegda, in an exciting progress update on the status of the facility and the impact of this transition on our customers.
Building the vision: Where we’ve been and where we’re headed
About 15 years ago, John reimagined his family business, M&S Centerless Grinding. The facility was small and dingy – a stark contrast to the bright and vibrant talent and potential housed within its walls. So, he spearheaded the renovation of a new addition that was lighter, brighter, and wickedly clean. Suddenly, the new M&S space set a new tone for its staff and customers. John was pleased that the company had finally begun operating as the premier grinding facility he envisioned – and he never looked back.
Fast forward to 2020, when M&S, Meron Medical, and KVI Group fused to form KMM Group, Ltd. Together, John and his new business partner Eric Wilhelm began dreaming about consolidating KMM under the same roof in a modern, cutting-edge facility. Knowing how transformative the M&S building upgrade was for his family operations and business, John felt compelled to steer KMM in the same direction. But this time, he and Eric reached for the stars – and caught them.
With John and Eric’s vision and help from their incredible team, the new KMM facility will feature:
- Approximately 100,000 square feet, including 74,000 on the first floor and 22,000 on the second floor
- Remarkable curb appeal with a clean, contemporary aesthetic inside and out
- High-end, high-capacity manufacturing environment
- 100+ milling, turning, grinding & EDM machines
- 4,000 square feet of R&D space
- ISO Class 8 Cleanroom
- Robust quality control areas
- 30-40,000 square feet of expansion area for dedicated equipment and projects
- Grand entrance with a natural light-filled atrium and staircase to the second level
- Modern cafeteria equipped with walls of refrigerators and microwaves and a café-style eating space
- Comfortable and contemporary lobby spaces
- Multi-purpose training center and conference room
- Breakout conference rooms outfitted with NEAT technology
- Well-equipped employee gym space
- Expansive automation space for engineers to tinker
- Professionally designed offices and workspaces for executive leadership, engineering, estimating, finance, and administration
“The new facility will allow us to add new capabilities to our mix, including laser processing and automation. I’m also looking forward to having nice employee amenities like the gym. I hope our team will be proud to work here.” – John Shegda, CEO, KMM
Building the foundation: Breaking down to build up again
The building that KMM purchased was constructed in the 1940s. Previous owners had expanded and renovated it several times until the 1980s. So, when we closed on the property, it looked like a time capsule. With a project of this magnitude, our team needed to begin from the ground up, tearing everything down, including 18,000 square feet of a too-low roof to accommodate higher elevations required for future equipment.
With much of the building deconstructed, the crew poured new floors to support new machines. The team opted for a 12” slab instead of the standard 6” to provide more stability. Then, the workers studded walls and roughed in updated electrical and plumbing lines.
At the time of writing, the roof decking and insulation installation are underway, and the new KMM facility is beginning to take shape.
Building excitement: The next phase gets underway
After the crews grind and polish the floors, they are gearing up to begin the interior finish work, including building out the new quality area on the first floor. By the end of February 2023, John and Eric expect that electrical and finishing work can begin on the building’s second floor. In addition, the ISO Class 8 Cleanroom is due in May, marking another highly anticipated milestone.
As the activity at the new facility continues to buzz, excitement is building among KMM staff. John and Eric enjoy giving employees tours of the new space, offering a glimpse into what they can expect to experience when they can finally occupy the new space in the summer of 2023.
“A decade ago, I wrote a vision for Meron Medical that said it would be operating out of a high-end, high-tech 100,000 square-foot facility that was bright and clean – and we’ve stayed true to that vision. It’s taken longer than I thought to come to fruition, but seeing it come together is surreal. We will no longer be limited by capacity or other restrictions – whatever we want to do, and however we want to grow, we can.” – John Shegda, CEO, KMM
Building a team: The people and faces inside the new facility
Fresh faces have joined our KMM team since construction began, including key players, such as a Six Sigma Black Belt Director of Continuous Improvement and Project Manager and Drexel Coop, who will help facilitate the relocation. These employees join an ultra-talented team of manufacturing leaders, craftspeople, and professionals who will become the heartbeat of the new facility.
We expect more aggressive hiring in Q4 of 2023 to fill new positions as our company expands its ever-growing capabilities in our quest to become a premier state-of-the-art contract manufacturing facility for mission-critical applications.
“Soon, our building will better represent the collaborative, innovative, and leading-edge company we’ve worked hard to cultivate for many years. We’re incredibly excited for this next phase.” – John Shegda, CEO, KMM