Build Your Dream Factory. Right the First Time.
From concept to commissioning, we design and deliver world-class greenfield manufacturing facilities that maximize efficiency, quality, and ROI
The Opportunity and the Risk
Setting up a new manufacturing facility is one of the most significant investments you'll ever make. It's an opportunity to:
- Incorporate the latest technology and best practices
- Design optimal layouts for maximum efficiency
- Build the right culture and capabilities from day one
- Position your business for decades of competitive advantage
But it's also high-risk. Poor decisions made during planning and setup can lock in inefficiencies, cost overruns, and operational headaches for years. The stakes are too high to learn through trial and error. You need experienced partners who've done this successfully many times before.
Why Greenfield Projects Fail
We've seen it repeatedly—greenfield projects that miss timelines, exceed budgets, and underperform expectations. Common pitfalls include:
Inadequate Planning
- • Underestimating complexity
- • Poor site selection criteria
- • Insufficient capacity planning
Technology Missteps
- • Equipment selection based on price
- • Over or under-automation
- • Technology incompatibility
Layout & Design Flaws
- • Inefficient material flow
- • Inadequate expansion space
- • Poor ergonomics
Vendor Management Issues
- • Unclear specifications
- • Poor coordination
- • Delayed deliveries
Capability Gaps
- • Insufficient hiring/training focus
- • Lack of SOPs
- • No startup plan
Regulatory Blindspots
- • Incomplete compliance
- • Permitting delays
- • Certification issues
The Result? Projects that go 20-50% over budget, launch 6-12 months late, and take 4+ years to reach stable operations—if they ever do.
The Idea Smith Greenfield Project Framework
Our End-to-End Methodology Ensures Success:
Concept & Feasibility
8-12 weeks
Detailed Planning & Design
8-10 weeks
Engineering & Pre-Execution
6-8 weeks
Construction & Installation
12-18 months
Commissioning & Ramp-Up
3-6 months
Handover & Continuous Improvement
Ongoing
Comprehensive Support for Every Phase
Strategic Consulting
- Feasibility studies and business case development
- Technology selection and vendor evaluation
- Financial modeling and funding strategy
Design & Engineering
- Process design and value stream mapping
- Layout planning and 3D modeling
- Equipment specifications and documentation
Project Management
- End-to-end project planning and execution
- Vendor management and contract administration
- Risk management and budget control
Operational Readiness
- Hiring strategy and organizational design
- Training programs and capability building
- SOP development and startup planning
Compliance & Certification
- Regulatory compliance roadmap
- Environmental and safety system design
- Industry certifications preparation
Real Impact: Stuffed Toy Greenfield Facility
The Challenge
A fast-growing Manufacturer and Exporter needed a new 110,000 sq ft facility to support 3x revenue growth over 5 years. Existing contract manufacturers couldn't deliver the quality and flexibility required.
Our Solution
Comprehensive greenfield project from site selection through commissioning:
- • Lean factory design with flexible production lines
- • Semi-automated packaging with manual flexibility
- • Integrated WMS for inventory control
- • Built-in expansion capability to 65,000 sq ft
- • SOPs and training for 85-person workforce
- • Maintaining Local and International compliance norms
Project Metrics:
Business Impact:
- Production capacity for ₹120 crores revenue (current: ₹40 crores)
- 20% lower production cost vs. previous contract manufacturers
- Ability to launch new products 40% faster
- Foundation for private label business (₹15 crores in year 2)
- Facility became competitive advantage in fundraising (₹25 crores Series A)
- Achieved 65% OEE in month 6 (industry standard is 15-18 months)
Why Partner with The Idea Smith?
Manufacturing-First Approach
We're manufacturing experts first, project managers second. We design facilities that don't just look good on paper but operate efficiently from day one.
Lifecycle Thinking
We optimize for total cost of ownership, not just initial capex. The decisions we make today will impact your operations for 20+ years.
Lean by Design
We embed lean principles from the start—optimal layouts, visual management, pull systems, and error-proofing built into the design.
Technology Pragmatism
We're not vendors pushing specific technology. We objectively evaluate what's right for your volume, product mix, and growth plans.
Risk Management
Our structured approach anticipates problems before they occur. We build in contingencies and alternatives to keep projects on track.
Knowledge Transfer
We don't just deliver a factory and walk away. We build your team's capability to operate and optimize the facility independently.
Proven Track Record
We've successfully delivered 15+ greenfield projects across diverse industries, from 5,000 sq ft to 100,000 sq ft facilities, with capex ranging from ₹5 crores to ₹25+ crores.
Building Smart from the Start
We help you integrate the right level of technology for your Industry 4.0 readiness:
Level 1: Foundation
- Computerized maintenance management system (CMMS)
- Basic production tracking and reporting
- Quality data collection and analysis
- Inventory management system
Level 2: Connected
- Real-time machine monitoring and OEE tracking
- Automated data collection from equipment
- Digital work instructions and SOPs
- Electronic batch records
Level 3: Intelligent
- Predictive maintenance using IoT sensors
- Advanced analytics and AI for quality prediction
- Digital twin for process simulation
- Integrated supply chain visibility
We right-size technology to your current needs while future-proofing for growth.
Let's Build Something Exceptional Together
Setting up a greenfield facility is complex, but it doesn't have to be risky. With the right partner, you can deliver on-time, on-budget, and set up operations that become your competitive advantage.
Start with a complimentary feasibility discussion. We'll review your concept, share our experience from similar projects, and outline a preliminary approach—no obligation.