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amarpreet41
- February 21, 2026
Some of the most rewarding consulting engagements start with a simple phone call.
That’s exactly how our journey with PVR Controls began.
The First Conversation
One afternoon, I received a call from Mr. Shresth Kanodia, Director at PVR Controls.
He had a clear vision:
- Build a world-class SMT manufacturing facility
- Scale output significantly
- Improve lead times and service levels to customers
He wanted to understand how Zenaca Consulting could support this journey – from concept to a fully running, high-performance factory.
We discussed my work in SMT and EMS consulting, and he immediately saw alignment with what PVR Controls wanted to achieve.
First Visit to Navi Mumbai
Soon after, I visited the PVR Controls office in Navi Mumbai.
That visit was important for three reasons:
- I understood their current operations, constraints, and ambitions
- We aligned on scope – not just equipment, but people, processes, and layout
- We built trust – the foundation of any long-term engagement
By the end of this phase, PVR Controls issued a purchase order to Zenaca Consulting to drive their SMT factory transformation.
The engagement had officially begun.
From Idea to SMT Line: Selection and Planning
The first major milestone was SMT line selection.
This is where many companies either overspend or under-design. Our focus was on:
- Matching equipment capability with current and future product mix
- Ensuring throughput aligns with business growth plans
- Balancing capex, flexibility, and maintainability
We worked through:
- Printer, pick-and-place, and reflow oven selection
- Inline inspection strategy – AOI
- Peripheral needs: loaders, unloaders, conveyors, baking ovens, printers, compressors, ESD infrastructure, etc.
Each selection was backed by data, not just brand names.
Layout and Peripheral Planning
Once the equipment strategy was clear, we moved to layout planning.
Key objectives were:
- Smooth material flow – from incoming stores to SMT, through to box build
- Minimal WIP accumulation and handling
- Clear separation of ESD-safe zones and controlled areas
- Future-ready design for additional lines and expansion
We created a layout that integrated:
- SMT line
- Material staging and kitting
- Rework and inspection areas
- Finished goods and dispatch flows
Peripheral equipment planning was done in parallel so that utilities, safety, and ergonomics were addressed from day one.
Building the Right Team
A world-class factory is not just machines and layout. It’s people.
PVR Controls understood this early, and together we invested time and effort into key hiring:
- GM – Operations
- To lead day-to-day execution, drive KPIs, and anchor culture on the shopfloor
- Warehouse Manager
- To bring discipline into inventory control, material movement, and traceability
- Supervisors and Executives
- Across production, planning, quality, and stores to support ramp-up
My role was to:
- Define roles and responsibilities
- Support shortlisting and interviewing
- Ensure selected candidates fit both the technical needs and the culture PVR Controls wanted to build
This combination of structured hiring and clear expectations gave the new factory a strong leadership backbone from the start.
Ramping Up: From Plan to Performance
With equipment installed, layouts frozen, and teams in place, we moved into ramp-up.
Focus areas included:
- Stabilizing process parameters – especially printing and reflow profiles
- Training on IPC standards, ESD, and basic problem-solving
- Implementing daily management routines – production meetings, line performance reviews, and issue escalation
The result?
The new factory started not just producing – it started performing.
Over time, production numbers ramped up to nearly 3X of previous outputs.
This wasn’t just a capacity story. It translated directly into:
- Faster turnaround times
- Improved on-time delivery
- Better customer responsiveness and confidence
Customers began to feel the difference:
- Shorter lead times
- More stable quality
- Higher confidence in scaling business with PVR Controls
A World-Class SMT Facility, Built with Intention
Looking back, the engagement with PVR Controls stands out because it covered the full spectrum:
- Strategy and scoping
- SMT line and peripheral selection
- Layout and material flow design
- Hiring and building the right leadership and operating team
- Ramp-up support and performance stabilization
What started as one phone call from Mr. Shresth Kanodia turned into a world-class SMT factory and a strong partnership.
For me, as a consultant, the most satisfying part was seeing:
- A clear vision
- Thoughtful investments in people and process
- And finally, a high-performing factory that is now serving customers faster and better than ever.
If your organization is planning to set up or transform an SMT facility, this journey is proof of what’s possible when vision, execution, and collaboration come together.