Transforming Ideas into Reality: The Step-by-Step Greenfield Success

Stratefix structured its approach to the greenfield project in phases, each crucial to establishing a successful and sustainable r-PET manufacturing plant.

Phase 1: Strategic Validation and Planning

1. 1. Market Validation and Feasibility Assessment: Stratefix initiated the project by conducting a market feasibility study to validate the demand for r-PET fibre in the Indian market, considering rising environmental awareness and supportive government policies. This study underscored the business viability and outlined potential challenges and competitive dynamics within the recycled polyester industry.
   2. Setting Objectives and Milestones: Once feasibility was established, Stratefix worked with the client to set clear objectives, defining milestones for plant construction, equipment setup, workforce hiring, and operational targets. This blueprint was essential for monitoring progress and ensuring alignment with long-term goals.
   3. Site Selection and Layout Design: Selecting the right location was critical to the project’s success. Stratefix identified an appropriate site in Surat, evaluating factors like logistical connectivity, resource availability, and cost. The consulting team then devised a detailed floor plan to optimise production flow and space utilisation, supporting both inward and outward inventory management.

Phase 2: Building Operational Foundations

1. 1. Standard Operating Procedures (SOPs): Stratefix developed comprehensive SOPs covering every aspect of operations, from raw material procurement to final product quality checks. These SOPs were instrumental in standardising processes, reducing potential errors, and ensuring product consistency, which is crucial in manufacturing.
   2. Inventory Management: Efficient inventory management was established to streamline the flow of raw materials and finished products. Stratefix implemented a robust system that improved inventory accuracy, optimised storage capacity, and enhanced visibility across different stages of production. This system contributed significantly to reducing operational costs and maintaining cash flow.
   3. Production Capacity Planning: Understanding the demand and forecasting requirements, Stratefix created a capacity plan to ensure the plant could meet production targets without overextending resources. This planning also helped establish flexible production scheduling to adjust for market demand fluctuations.

Phase 3: Workforce Development and HR Infrastructure

1. 1. HR Strategy and Organisation Structure: To support a greenfield project, an efficient HR strategy is vital. Stratefix structured a full HR team, responsible for setting up company policies, recruitment, and manpower planning. They outlined a comprehensive organisation structure with well-defined roles to support both operational and administrative functions.
   2. Job Descriptions, KRAs, and KPIs: For effective workforce management, Stratefix developed clear job descriptions, Key Result Areas (KRAs), and Key Performance Indicators (KPIs) for each role. This clarity helped employees understand their responsibilities, facilitated goal setting, and fostered a culture of accountability across all levels.
   3. Sourcing and Training: Stratefix conducted a thorough recruitment process to ensure that employees aligned with client’s sustainability goals and operational demands. The new hires underwent rigorous training in quality control, production processes, and compliance standards, ensuring they were equipped to contribute effectively from day one.

Phase 4: Technological Integration and ERP Implementation

1. 1. ERP System Selection and Implementation: Recognising the importance of technology in manufacturing, Stratefix identified a suitable ERP solution that could centralise client’s operations across finance, human resources, manufacturing, and supply chain. The ERP system improved data security, standardised data, and facilitated compliance, ensuring that the client maintained operational transparency.
   2. Human Resource Management System (HRMS): To streamline HR functions, Stratefix implemented an HRMS that simplified payroll, attendance, and employee data management. This system also enabled efficient communication and reporting, which was critical for managing a large and diverse workforce.
   3. Data-Driven Decision Making: Regular internal audits and data assessments, facilitated by the ERP, helped identify areas for improvement in real time. This data-driven approach allowed the management to make informed business decisions, optimise resource allocation, and reduce risks associated with system failures or compliance gaps.

Phase 5: Quality Control and Risk Management

1. 1. Quality Assurance Framework: Stratefix set up a rigorous quality assurance framework to maintain high production standards. This included implementing quality checks at each stage of the production process, from raw material intake to final packaging, ensuring that products met industry standards.
   2. Risk Assessment and Mitigation: Stratefix conducted a thorough risk analysis, identifying potential operational risks, such as human error and equipment breakdown. Proactive policies and preventive measures were introduced, including emergency protocols, periodic equipment maintenance, and workforce training for rapid response.
   3. Sustainability and Compliance: Given client’s commitment to sustainability, Stratefix ensured all operations adhered to environmental regulations and implemented waste management practices. The consulting team also advised on future-proofing the plant by anticipating regulatory changes and adopting practices that reduced the environmental footprint.