ABB

When ABB secured a major contract to produce a next-generation robot for a leading U.S. retailer, its North American Robotics headquarters in Auburn Hills needed a transformation. The 40-year-old, 540,000 s.f facility housed multiple business units and had disjointed production and logistics operations located at opposite ends of the building. While relocation was considered, the site’s proximity to key automotive clients and heavy-duty industrial infrastructure made it a valuable asset. Aging systems, outdated offices, and evolving business demands posed major challenges to modernizing the space while maintaining continuous operations.

Stream’s Manufacturing, Food & Beverage, and Distribution team developed a four-phase strategy to optimize the facility and deliver long-term value. Early phases focused on relocating and reconfiguring industrial operations to accommodate a new robotics production line. The east office wing was fully redesigned to improve team collaboration and workforce engagement, while a state-of-the-art client experience and training center was constructed to enhance ABB’s customer-facing operations. Stream worked closely with local authorities to navigate evolving code requirements and maintained flexibility throughout the project to adapt to labor shortages, long lead times, and shifting program requirements—all while keeping the facility 100% operational.

ABB increased production capacity by 30% and the Stream team delivered over $3M in project cost avoidance and savings. The new office environment improved employee morale and collaboration, while the training center streamlined customer onboarding and technical support. As ABB’s pilot site for its Mission to Zero initiative, the project also identified energy conservation measures to save 66% of current energy consumption – identifying $553,000 in annual cost savings and a roadmap to achieve Net Zero Carbon within four years.