Case Study: Greenfield Plan
Start-Up in India
Building a Touchless, Lights- out Plant from Day One
Background & Context
In developing markets, fabric care plants are usually labor-intensive because automation costs are high. Globally, there was no precedent for a fully touchless or lights-out factory in such markets.
In India, PacersGlobal set out to change that—building a fully automated, contractor-free greenfield plant capable of vertical start-up from day one. Historically, packaging had been outsourced, bringing in cultural and reliability challenges. This project redefined what was possible.
The Challenge
How can we build an affordable, fully automated, contractor-free plant that delivers vertical start-up and sustained reliability from day one—challenging decades of manual and contractor-dependent models?
Strategic Actions Taken
✅ Conducted Vendor Acceptance Testing (VAT) to identify equipment weaknesses early
✅ Established Set Points for ramp-up, steady-state, and ramp-down operations
✅ Defined vertical start-up strategies for lead and rollout lines
✅ Implemented technology transfer & structured operator training
✅ Executed post-startup checklist with cross-functional sign-off
✅ Performed material variability analysis and process window definition
✅ Integrated automated quality checks from day one to eliminate human error
✅ Created defect prevention checklists to sustain reliability
Leadership & Cultural Shift
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Built a culture of ownership, not dependency
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Ensured leadership alignment on cost, quality, and reliability goals
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Empowered employees with world-class training and systems thinking
Lessons Learned & Key Takeaways
🏭 Zero contractors from day one — entire workforce in-house
🤖 Fully automated, touchless operations—first of its kind in India
🚀 Vertical start-up success with top performance within 2 months
🌍 Recognized globally as a “Factory of the Future” model site
💡 Sustainable reliability through Initiative Management and training
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Contractor-free automation is achievable with the right systems
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Initiative Management ensures reliable vertical start-ups
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Crew involvement during validation builds strong technical mastery
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Investing early in training ensures lasting performance
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The case studies contained herein are the exclusive property of PacersGlobal. Utmostcare has been taken to maintain the confidentiality of client identities, site names, andproprietary work systems, including those that are patented or trademarked. Anyunauthorized use, reproduction, distribution, or disclosure of this information, in whole orin part, without the prior written consent of PacersGlobal, is strictly prohibited and mayresult in legal action. Violators shall be held liable and subject to prosecution underapplicable laws in a court of law.