From site selection to first production run delivered

Launching a manufacturing site is one of the most exposed investments a company makes. Multi-year timelines, eight- or nine-figure capex, regulatory complexity in multiple jurisdictions, and a new workforce to build from scratch. An interim manager who has delivered greenfields before removes the execution risk that sits between the investment decision and the first shipped product.

When you need this engagement

Typical triggers for a greenfield mandate include:

• A group or OEM expanding manufacturing capacity into Central or Eastern Europe for the first time
• A private equity sponsor backing a platform that requires a new production site as part of the investment thesis
• A supplier winning a new programme that requires dedicated capacity outside the existing footprint
• An acquiring company that needs to stand up a new site in parallel with an M&A process

In each case, internal teams often lack direct experience of running a greenfield to completion. The cost of learning on the job is measured in months of delay and millions in overrun.

What I deliver

A greenfield engagement typically covers the full arc from investment decision to operational handover:

• Site selection and due diligence. Location shortlisting against operational, logistical, labour-market and incentive criteria. Coordination with economic development agencies, special economic zones and regional authorities.
• Permitting and regulatory approvals. Environmental impact assessments, building permits, occupational safety approvals and industry-specific certifications (IATF 16949, ISO 14001, ISO 9001, ISO 50001 and others as required).
• Construction and fit-out oversight. Client-side project management across general contractor, MEP subcontractors, utility connections and infrastructure.
• Equipment specification and commissioning. Working with process engineering to specify production equipment, manage supplier selection, oversee installation and run acceptance testing.
• Workforce build-up. Recruiting the local leadership team, defining the organisational structure, hiring and training production operators, establishing shift patterns and pay structures.
• Start-up and SOP certification. Running the ramp-up, achieving customer PPAP / first article approvals, passing customer and regulatory audits, stabilising to planned output.
• Handover. Transitioning operational control to a permanent plant director either recruited during the engagement or nominated by the client.

Typical timeline

A full greenfield mandate runs 12 to 18 months end-to-end, depending on complexity, regulatory environment and equipment lead times. Engagements are structured around four milestones the client can track:

What clients take away

• A fully operational manufacturing site, ramped to planned output, with certified SOPs
• A permanent local management team in place and handover complete
• All regulatory approvals and customer certifications secured
• Full project documentation and reporting history for investor due diligence
• Capex discipline: projects delivered within budget or with variances fully explained