Greenfield Manufacturing & Ramp-Up
New factories designed lean from day one, and ramped up fast.
A greenfield site is a rare chance to design waste out before it exists. We help you plan new manufacturing operations in Australia or Asia, from the business case and site selection to a lean factory layout, equipment, people, systems and certification.
Then we manage the production ramp-up, the most underestimated phase of any new operation, with structured ramp plans, standard work, daily management and rapid problem solving, so you reach rated capacity and quality targets sooner.
- Companies building or fitting out a new factory
- Manufacturers adding a new production line or site in Asia
- Operations struggling to reach rated capacity after a launch
Greenfield factory and ramp-up roadmap.
Every engagement follows a clear, staged process with defined decision gates, so you always know where your project stands and what happens next.
- 01◆ GateBusiness caseSite selection and investment
- 02Lean designFlow-first layout
- 03Build & equipConstruction, FAT and SAT
- 04People & systemsHiring, training, QMS, ERP
- 05◆ GatePilot runsValidation and certification
- 06Ramp-upWeekly targets to rated capacity
- 07OptimiseKaizen and OEE improvement
Greenfield Manufacturing & Ramp-Up services.
Select a service to see what is included, what you receive and the benefits.
Site Selection & Business Case
The right location, justified by the numbers.
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Lean Factory Layout & Design
Design the flow first, then the building.
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Equipment Specification & Procurement
The right machines, specified and bought well.
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Workforce, Training & Standard Work
People ready before the first part is made.
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Production Ramp-Up Planning
Reach rated capacity and quality, fast.
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QMS Setup & Certification
A quality system ready for certification from day one.
Learn moreProcesses we source, set up and manage.
From plastics and sheet metal to castings, machining and electronics, we manage the processes behind your product in Australia, China and across Asia.
Plastics
- Injection moulding
- Overmoulding & insert moulding
- Two-shot moulding
- Blow moulding
- Extrusion
- Thermoforming
Sheet metal
- Laser cutting
- Sheet metal folding & bending
- Progressive stamping
- Drawing & deep drawing
- Metal spinning
- Welding & fabrication
Machining & casting
- CNC milling
- CNC turning
- Sand casting
- Pressure die casting
- Investment casting
- Forging
Electronics & assembly
- PCB assembly (SMT)
- Cable & wire harness
- Electro-mechanical assembly
- Testing & programming
- Cleanroom assembly
- Packaging
Finishing
- Powder coating
- Anodising
- Plating
- Pad & screen printing
- Laser marking
- Texturing & polishing
What changes for your business.
Lean by design
Flow, layout and material handling optimised before construction.
Faster ramp-up
Rated output and quality reached weeks or months sooner.
Certified and capable
Quality systems and trained people ready from the first production run.
Greenfield Manufacturing & Ramp-Up: common questions.
What does a lean factory layout mean?
It means designing material and people flow first: short, straight paths, point-of-use storage, cells that match product families and space for visual management. Buildings are then designed around the flow, not the other way around.
Can you help us reach full production faster?
Yes. We create a ramp-up plan with weekly targets, run daily performance reviews, solve problems quickly at the source and coach supervisors so output and quality climb steadily.
Concept and business case in 4–8 weeks; design to ramp-up over 6–18 months.
Every engagement starts with a free consultation and a fixed-scope proposal with clear deliverables, timing and success measures.
Articles on Productivity.
Standard work in high-mix manufacturing
Standard work is easy in repetitive production and harder in high-mix, low-volume environments. How to standardise what repeats, structure what varies and make standards useful when every job seems different.
Capacity planning for growth without new capex
Before buying another machine or building another factory, most manufacturers have significant hidden capacity in their existing assets. How to measure it, release it and plan growth with confidence.
Case studyCase study: capacity released without new presses
A Queensland moulder believed its plant was full and prepared a case for three new presses. A detailed capacity model found 2,900 press hours a year hidden behind high utilisation, enough to defer about $1.6 million of capital.
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Whether it’s a bold new product, a strategy that needs sharpening or an operation that should be doing more, a conversation with a senior consultant is the fastest way to find out what’s possible.
- Free initial consultation with a senior engineer
- Response within one business day
- Confidentiality and NDA available on request
Prefer to give us the full picture? Use the detailed project enquiry form