DP Electric’s Prefab Shop is built to support efficiency, quality, and innovation across every phase of production. Through a strategic expansion and process improvements, the shop has been transformed into a space that better serves both the field and the teams who support it.
The shop was expanded by 12,000 square feet, creating room for increased production and improved workflow. The additional space allowed the team to double the conduit bending areas, hanger station, and welding stations. New dedicated sections were added for box builds, panel and wireway assemblies, and underground work, improving organization and consistency throughout the shop.
To better support field operations, the prefab team introduced new shipping and installation carts that make organization and transport easier and more efficient. These carts help ensure assemblies arrive on site ready for installation.
A major upgrade to the shop includes a full sheet rotary CNC machine that produces micarta labels in bulk. Previously, each label was made individually. The new process allows labels to be produced faster and with greater precision, saving time and improving consistency.
The expanded layout was designed to keep work flowing smoothly from start to finish. Materials move in a straight path through the shop, and vendor managed inventory ensures the right supplies are available when needed. This setup helps new team members get up to speed faster and allows issues to be identified earlier in the process. Finished assemblies move directly to the shipping area, aligned with the forklift path for faster loading and delivery.
Technology plays a key role in daily operations. Digital workstations allow team members to access models directly at their stations, reducing errors and limiting paperwork. A digital work order system keeps the shop and field connected, making progress easier to track. A jig table supports faster repetitive builds, and a growing Andon system helps the team stay aligned on workflow and communication.
Sustainability and safety guided many of the improvements. Standardized builds and vendor managed inventory help reduce waste, while digital tools limit paper use. A cutting app improves material usage and reduces scrap. Reusable carts have replaced most shipping boxes and pallets, cutting down on excess packaging. Adjustable workstations, rolling carts, and anti fatigue mats create a safer and more comfortable work environment.
The Prefab Shop reflects DP Electric’s continued investment in better tools, smarter systems, and the people who make the work possible. Through intentional design and the use of new technology, the shop supports productivity while maintaining the quality standards our teams and clients expect.
