The Situation
The new site needed to support multi-year growth and export complexity, not just current volume.
The major risk was design drift during execution - where late layout reality causes schedule and cost escalation.
The business needed buildability certainty before steel and civil commitments.
What We Did
We designed for actual run conditions and validated layout decisions on site before construction start.
- Sized future capacity and specified machinery for projected growth.
- Designed L-shaped material flow and inventory norms for RM, WIP, and FG.
- Built automation in from day one with articulated forklifts, AMR systems, and rack-supported mezzanine storage.
- Validated operations-fit and issued detailed cost estimate before build start.
The Results
The plant was commissioned on schedule and constructed exactly to design with no construction-stage modifications.
The facility came online certification-ready with integrated automation and growth-sized capacity.
The pre-build estimate held through commissioning, improving financial confidence at board level.
Strategic Takeaway
- Greenfield value comes from designing for future plant behavior, not current constraints.
- When design is validated on operations reality before build, schedule and budget hold.
Contact Gemba Concepts
Need Help Solving Similar Execution Gaps?
Connect with our consulting team to discuss your current operational challenge and the outcomes you want to achieve.
Bengaluru
Ram Leo, 59/4, Market Rd, Basavanagudi, Karnataka 560004
Ahmedabad
World Trade Tower, Near Sarkhej Sanand Cross Road, Gujarat 380051
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