Designing Improvement
MINNEAPOLIS / ST. PAUL (07/20/2026) — For their Senior Design Project, seniors Allison Albrightson, Thang Do, Mira Patel, Chase Trygestad and Jakob Zeller worked with Viking Aluminum, a Minneapolis-based startup that specialize in prefabricated aluminum balconies. The team was tasked with designing an in-house assembly facility within the company’s newly acquired space to improve production efficiency, reduce lead times, and enhance delivery reliability.
Before acquiring the new space, Viking Aluminum relied on an out-of-state third-party contract manufacturer who would receive components from suppliers, then assemble the railings and decks before shipping them to Minnesota where the final product would be fully assembled on the job site. Because of the reliance on a third-party, combined with increasing demand and geographic distance, shipping delays and late penalties, Viking Aluminum decided to fabricate in-house.
With the new space serving as a blank slate, the ISyE team utilized the Plan-Do-Check-Act (PDCA) framework to help them develop a layout capable of supporting Viking Aluminum’s need for an efficient assembly system.
In the ‘Plan’ phase, the team conducted site measurements, identified required equipment and tooling, and defined the key process steps necessary to internalize production. To complete the ‘Do’ phase, the team developed multiple facility layouts using BluBeam Software to build and visualize workflow, material movement and space utilization.
Based on the feedback gathered during the ‘Check’ phase, the team optimized the design that best aligned with operational needs, improved efficiency, and was practical for implementation with the given space. Once the adjustments were addressed, the team moved to the ‘Act’ phase, which completed the framework.
The final main deliverable included a detailed facility floor plan that will be capable of supporting Viking Aluminum’s ultimate production goal of 2,200 balconies by 2027.
The ISyE team presented their floor plan to their project sponsors, which included their process, as well as a risk management assessment that addressed found spatial constraints that could potentially limit the effectiveness and clarity of the assembly line design.
Ultimately, Viking Aluminum approved of the final floor plan.
Project sponsor and Viking Aluminum owner Ben Swenson states, “I can’t say enough good things about the students and their excitement. We are grateful for this opportunity to work with them, ISyE and the University of Minnesota.”