SIG SAUER's Agile Expansion: How Smart Manufacturing Fuels Next-Gen Defense

Newington, NH – November 5, 2025 – SIG SAUER has been awarded the 2025 Associated Builders and Contractors (ABC) Chairman's Award for Excellence in Construction, recognizing the complex expansion of a live-fire range within its Newington, New Hampshire manufacturing facility. While accolades are common for SIG SAUER, this award isn’t just about bricks and mortar; it signals a strategic commitment to agile manufacturing and a nimble response to critical national defense needs – all achieved without interrupting ongoing production.

This expansion wasn’t simply about adding square footage. The project involved installing a 328-foot-long steel firing tube, constructed in 30,000-pound sections and suspended over an active manufacturing floor, and integrating additional specialized test ranges. The facility is designed to support high-volume climate-controlled testing for the U.S. Army’s Next Generation Squad Weapons (NGSW) program – a program poised to fundamentally modernize infantry capabilities. What sets this project apart, however, is that SIG SAUER accomplished this ambitious construction while maintaining full production output – a feat requiring meticulous planning, advanced project management, and a commitment to operational resilience.

Meeting the NGSW Challenge – and Keeping Guns Shipping

The NGSW program represents a significant investment in the future of American infantry weaponry. The Army is seeking to replace existing firearms with a more accurate, reliable, and lethal system. SIG SAUER won a key contract in 2022 to provide the XM7 rifle and XM9 machine gun – the centerpiece of the NGSW initiative. This win immediately placed increased pressure on SIG SAUER’s manufacturing capabilities. “The Army needed a partner who could not only deliver a superior weapon system but also scale production rapidly and reliably,” explained a source familiar with the program. “SIG SAUER understood that challenge and invested accordingly.”

Expanding testing capacity concurrently with ramping up production wasn’t a matter of simply adding more room; it required a re-thinking of manufacturing workflow. The company adopted a phased approach to construction, carefully coordinating building activities with ongoing production runs. “It was a complex dance,” said an industry analyst specializing in defense manufacturing. “They essentially built a testing facility within an operating factory. It demanded an exceptional level of coordination and a flexible manufacturing process.”

Resilience by Design: The Keys to Concurrent Operation

SIG SAUER’s success in completing this project without disruption hinged on several key factors. Firstly, extensive pre-planning and modeling were undertaken to minimize construction impacts. Detailed simulations were used to optimize construction sequencing and identify potential bottlenecks. Secondly, advanced project management techniques, including just-in-time delivery of materials and real-time monitoring of construction progress, were employed. This ensured that materials arrived when needed and that any issues were addressed promptly.

Furthermore, the company leveraged its existing expertise in lean manufacturing principles. This involved streamlining processes, eliminating waste, and optimizing workflow to maximize efficiency. “They’ve been investing in advanced manufacturing technologies for years,” explained a source within SIG SAUER. “This expansion was an opportunity to put those investments to the test.”

The company also prioritized employee communication and collaboration. Regular meetings were held to keep employees informed of construction progress and address any concerns. This fostered a sense of shared ownership and helped to ensure a smooth transition. “Keeping the workforce informed and engaged was absolutely critical,” noted the industry analyst.

Beyond the NGSW: A Model for Future Manufacturing?

The SIG SAUER expansion isn’t just significant for the defense industry; it offers valuable lessons for manufacturers across various sectors. In an era of increasing supply chain volatility and rapidly changing market demands, the ability to adapt quickly and maintain operational resilience is paramount. The company’s approach – combining meticulous planning, advanced technology, and a commitment to employee engagement – provides a blueprint for manufacturers seeking to navigate these challenges.

“This project demonstrates the importance of investing in flexible manufacturing capabilities,” said the source familiar with the NGSW program. “Companies that can adapt quickly to changing conditions will be best positioned to succeed in the long run.”

The ability to maintain production while expanding capacity highlights a core tenet of modern manufacturing: agility. SIG SAUER’s success serves as a powerful case study in how companies can not only meet the demands of critical national defense programs but also build a more resilient and adaptable manufacturing operation for the future. The award isn’t just a recognition of a completed construction project; it’s a testament to a strategic vision and a commitment to innovation in the face of complex challenges.