Operations practice
From bare land to trial production — and then to a plant that runs without you
Site appraisal, process design, plant layout, machinery selection, commissioning and the SOP system that keeps output stable after we leave. Plus OEE turnarounds for plants already running.
Typical outcome profile
You are probably here because
One of these sounds familiar
- 01
Machinery suppliers are quoting you a plant design. That is a conflict of interest.
- 02
Your line is rated 5 tonnes an hour and does 2.8 on a good day.
- 03
Output depends on which supervisor is on shift.
- 04
Rework and yield loss are real numbers nobody has ever calculated.
- 05
Commissioning is six months late and no single person owns the schedule.
Our approach
How we actually do this work
Not a methodology diagram. This is the sequence, in order, with the uncomfortable parts left in.
- 01
Design the process, then the building
Mass balance first: what goes in, what comes out, what is lost, at what moisture and temperature. Buildings and machinery follow from that, not the reverse.
- 02
Lay out for material flow
Single-direction flow, segregated raw and finished zones, hygienic-design compliance for food, and utility runs planned before the civil drawings are frozen.
- 03
Specify and tender machinery independently
We write the technical specification, run the tender, evaluate three quotes on total cost of ownership and negotiate the performance guarantee. We take no commission from any supplier, ever.
- 04
Commission against a checklist
Water trials, product trials, yield validation, OEE baseline and a defect log closed before the final payment to the supplier is released.
- 05
Hand over a system, not a building
SOPs at the workstation, shift handover formats, a daily production board, preventive maintenance calendar and two weeks of supervisor training on the floor.
What you receive
Deliverables, with the week they land
Every item below appears in the engagement letter with a date against it. If a date slips, you hear it from us first.
Site appraisal & process design
Week 3Mass and energy balance, utility load calculation, effluent load estimate, and a scored comparison of up to three candidate sites on freight, power, water, labour and effluent cost.
Plant layout & equipment schedule
Week 6Block layout, detailed equipment layout, material and personnel flow diagrams, utility routing and a line-item equipment schedule with specifications.
Machinery tender & evaluation
Week 9Technical specification documents, vendor shortlist, comparative evaluation on total cost of ownership, and negotiated performance guarantees.
Project management to commissioning
Through executionWeekly site coordination, a live critical-path schedule, contractor reviews, and a commissioning protocol with trial-run acceptance criteria.
SOP & operating system
Month 2 post-commissioningWorkstation SOPs, quality control plan, preventive maintenance calendar, shift reporting formats and a trained supervisory layer.
Measured results
Medians across delivered engagements in this practice, not best cases. Our full methodology is in the about page.
42
Greenfield plants commissioned
Dairy, food, bakery, pharma-adjacent
+24 pts
Median OEE improvement
On brownfield turnarounds
11%
Capex saved vs. supplier design
Median, on independently tendered projects
Engagement models
Indicative fees, published
Final fees depend on scope, travel and project size, and are fixed in the engagement letter before work starts. There are no hourly surprises.
Plant Feasibility & Layout
Project₹1.5 – 5 lakh
Promoters deciding what to build and what it will cost
- Process and mass balance design
- Capacity and utility sizing
- Block and equipment layout
- Indicative capex estimate
- Equipment schedule
Turnkey Project Management
Project2.5 – 5% of project cost
Greenfield plants from land to trial production
- Everything in Feasibility & Layout
- Machinery tender and negotiation
- Civil and utility coordination
- Site supervision and schedule control
- Commissioning and trial runs
- SOP handover and training
Operations Excellence
Retainer₹1.25 – 3 lakh / month
Running plants stuck below 70% OEE
- OEE and yield baselining
- Bottleneck removal programme
- SOP and quality system rollout
- Supervisor capability building
- Monthly performance review
Questions
What clients ask before engaging
If your question is not here, ask it on the call. We answer pricing and scope questions directly.
Operations practice
Talk to the partner who runs factory setup & operations
Forty-five minutes, no deck, no junior. You will leave the call knowing whether this is the right work for you and roughly what it costs.
- Call
- +91 98765 43210
- Response
- Median 5h 40m in business hours