BEI Associates, Inc. designed the Ford Windsor Engine Plant expansion and renovation project.  The expansion was necessary in order to increase engine production by 150,000 engines per year.  The site-wide engine production facility manufactures the 4.6L, V6, 5.4L, V8 and 6.8L V10 engines. 

The first phase of the project took place in the existing Windsor Engine Plant #2, now known as TME-WEP.  This consisted of expanding the V10 Crank Shaft production facility.  The second phase of the project consisted of both a major addition and renovation of the existing Plant #1 known as TME-WEP #1.  The building addition was 130,000 square feet.  The renovation was 60,000 square feet of the existing WEP #1.  This facility's total square footage is now 190,000 square feet.  This expanded facility houses a crank shaft piston, rod and block.

Unique to this project, was that BEI established it's own on-site engineering office.  It was BEI's feeling that this requirement ensured Ford of fast-pace engineering, stronger client communication, increased client involvement throughout the design process and thus, superior client satisfaction.  All work was done while full production at the facility continued. 

BEI was also commissioned by Ford Motor Company to conduct a Detailed Facility Study (DFS) of the Windsor Engine Plant production facility.  The purpose of the study was to confirm the project's scope of work, the different construction schedules, the development of the designs, and to validate the proposed budget for renovations and building additions. 

The DFS demonstrated that all of the existing production functions were being maintained at the existing capacity with little or no disturbance while the facility structure was undergoing change.