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5 Key points for Greenfield Projects via Lean Facility Design (LFD)

  • By faber
  • February 26, 2022

A greenfield project is when construction begins from the ground up. It’s a plot of land where no previous development has taken place, and no demolition or reconstruction work has been done.

A greenfield project is one that is created on land that has never been used before and does not require the reconstruction or demolition of any existing structures. It’s a project that starts from the ground up, with no constraints imposed by past work on the property, such as an existing structure or infrastructure.

On undeveloped greenfield land, it can comprise infrastructure, industrial, manufacturing, and urban development projects. New factories, power plants, and airports built from the ground up on greenfield land are examples of greenfield projects.

Faber Infinite’s Lean Facility Design (LFD) is a one-of-a-kind toolset (methodology) that helps companies create best-in-class factory layouts.  LFD framework has been implemented for Remsons Industries Ltd, a pioneer in India for Auto Control Cables and Gear Shifters with Push-Pull Cables, when they were shifting their facility. They got the new plant layout done by Faber Infinite. We helped them map out all the processes including raw materials, stores, material flow, movement between material flows taking into consideration COVID norms as well.

Similarly, Goldi Solar Private Limited, one of the fastest growing Solar PV module manufacturing companies deployed our patented Lean Facility Design© (LFD) framework for their new facility for efficient processes and operations. The client was extremely intrigued with LFD framework and got superlative results.

Yet another leading drip irrigation pipes manufacturer, Kothari Agritech Pvt Ltd resorted to Lean Facility Design framework for top class productivity and capacity and thus built a world class plant. They were in the process of consolidation of 6-7 units at a new facility called Kothari Udyam Nagar in Solapur. They wanted to design a world-class layout and Team Faber supported them in setting up top-notch facility with higher than planned capacities and manpower productivity.

When constructing a Lean facility from the ground up, there are often numerous project rollout phases:

Map current-state and ideal-state processes

This phase includes “baselining” the present state and identifying “future-state” mapping, as described in more detail below. The main purpose is to figure out what the organisation as a whole, and the facility in particular, require and should provide. The concept of value stream mapping and understanding the client journey take centre stage in this phase, and lean thinking is essential.

Create a process model

Because the costs of implementing a design and process from scratch can be significant, many businesses opt to model their design and process. Modeling bridges the gap between action and outcome, enabling for more effective iterations and improved results. Using Lean thinking throughout the modelling phase guarantees that the chosen design pulls value through the process, minimises defects, and delivers one-piece flow—all of which are principles aimed at enhancing customer value and increasing efficiency. In terms of production output and end-of-shift inventory levels, a model can indicate the impact of running two eight-hour shifts versus three.

Devise a strategy

This phase combines the existing state, ideal state, and unique conditions at the new site to produce an executable, in-scope design. Personnel selection, raw material and waste management, customer consumption process and experience, and everyday work experience of staff at the new facility are all design processes that must be strategically (and realistically) considered.

Create an implementation plan

The ensuing blueprint, based on the outcomes of the modelling efforts, specifies precisely each step essential for effective implementation.

Design to Production ­­

Crossing the bridge from design to implementation is the final step, which necessitates careful consideration of human infrastructure and resources. A greenfield project has the advantage of allowing developers to start from scratch and design a project that meets both current and future needs. They will also have complete architectural flexibility with the project because they will not be required to demolish or alter anything on the site.

It is the need of the hour with more and more manufacturing units being set up across industries. Lean Facility Design focuses on aspects like flow design, capacity calculations, manpower and equipment optimization, material handling, beyond optimal layout design. It also covers aspects like project planning, conceptual design at the systems level, functional design at the value stream level, and detailed design at the operational level, standard work development for operating. LFD is a proven and copyrighted methodology, that supports organizations to build best-in-class facilities from day zero!

Written by Faber Aleena & Compiled by Faber Mayuri